netl gasification systems...gasifier designs to increase syngas heating values, reduce reactor size,...

NETL GASIFICATION SYSTEMS

The Gasification Systems Program at NETL is focusing on high-performance, modular, small-scale gasification systems to reduce investment risk, enhance reliability, and create alternative markets for coal through a diverse and cutting-edge research portfolio.

A Modular Approach to Traditional Gasification

Key Program Technology Areas

Reduce Investment Risk

Thinking Beyond Economies of ScaleSmall systems enable lower project risk.

FY 2020 BUDGET REQUEST

CONTACTS

DIRECTOR (ADVANCED ENERGY SYSTEMS):

Regis Conrad

PROGRAM MANAGER:Jai-Woh Kim

TECHNOLOGY MANAGER: David Lyons

TECHNICAL PROFOLIO LEAD: Jonathan Lekse

PARTNERS

Modular units allow for more flexible operation.Improve efficiency through innovation.Create secure, stable, and reliable power (resilient).Modular systems are small and can be built faster.Fundamentally transform how plants are designed.

$10,300k

Enhance Reliability

Create New Coal Markets

Coal FIRST Goal: Develop coal plant of the future to provide

secure, stable, and reliable power.

Innovative new methods for oxygen production, including membranes,cryogenics, and oxygen carriers!

Create a CO2-negative coal

plant using carbon-neutral

biomass and carbon

capture (BECCS)!

Improving gasifier designs to increase syngas heating values, reduce reactor size, and lower oxygen demand!

Fischer-Tropsch synthesis

optimization, enabling the

creation of high-quality liquid fuels!

Modular system flexibilitymakes coal products more accessible to more industries. Byproduct reuse and improved coal-to-liquids performance reduce the costs and environmental impacts of using coal!

Warm-gas cleanup, innovative refractory materials, and low thermal input gasification (such as with microwaves) can greatly reduce maintenance and shorten plant downtimes, for highly reliable power and/or chemical production!

Smaller sizes means lower initial capital investment! Faster construction means shorter payback periods! Lower baseline emissions means lower likelihood to lose profits to regulation compliance!

Development of tailored oxygen carrier materials for oxygen production for gasification reactions and other applications.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

NETL FWP 1022405, Task 5.1

CONTACTS

HQ PROGRAM MANAGER:Jai-Woh Kim


FEDERAL PROJECT MANAGER: Jonathan Lekse

PRINCIPAL INVESTIGATOR: Johnathan Lekse

DOE Share: $3,419k

Total Award Value: $3,419k

This task is developing tailored oxygen carrier materials for uses in anoxygen production module that can be added to a gasification systemas an in situ source of oxygen for gasification reactions. These carriermaterials will have tunable oxygen delivery properties to respond to avariety of opportunities and fuels. Aside from innovative carriermaterials, designs for an oxygen production module and an optimizedprocess to produce syngas using a combination of coal and oxygencarriers are under development.

The modular systems that are currently being studied could benefitfrom the use of an oxygen carrier material if that carrier can be madecompetitive with a scaled-down cryogenic process in terms of cost andefficiency. Perovskite materials under development as carriers arefavorable as a type of stable material that can rapidly and reversiblystore and release large quantities of oxygen due to theirnonstoichiometric nature. Ferrite materials under development havebeen shown to have thermodynamics that favor the partial oxidationof coal to carbon monoxide (CO) instead of the complete oxidation tocarbon dioxide (CO2), which makes them ideal for gasificationreactions.

• High conversion of H2 (~80%) wasachieved during steam oxidation at800°C.

• 25-cycle test with oxygen carrierreduction with coal and oxidation withsteam showed very stable performance.

• A computational fluid dynamics(CFD)/Multiphase Flow with InterphaseeXchanges (MFiX) module is currently indevelopment. Experimental/CFD resultswill be used to expand current MFiXmodel to a full pressure-swingadsorption (PSA) simulation.

Oxygen Production for Gasification

PERFORMER

North Carolina State University will develop and demonstrate aradically engineered modular air separation unit (REM-ASU) forsmall-scale coal gasifiers. Compared to state-of-the-art separationtechnologies, the REM-ASU will have reduced capital costs andenergy consumption. The REM-ASU technology will bedemonstrated at pilot scale, generating commercialimplementation data. Three approaches will be used: (1) oxygensorbent (OS) synthesis, characterization, and screening; (2) pilot-scale OS production and pilot REM-ASU unit design, construction,and operation; and (3) process and techno-economic modeling.

Radically Engineered Modular Air Separation System Using Tailored Oxygen Sorbents

Design and demonstrate a modular air separation unit small-scale gasification.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031521

CONTACTS



FEDERAL PROJECT MANAGER: Diane Revay Madden

PRINCIPAL INVESTIGATOR: Dr. Fanxing Li

PARTNERS

DOE Share: $2,044k

Performer Share: $520k

Total Award Value: $2,564kA successful project may result in advanced oxygen sorbents with

greater than 2 weight percent oxygen capacity and high activity;robust, steam-resistant oxygen sorbents with high-equilibriumoxygen partial pressure to allow effective oxygen generationwithout a vacuum desorption step; a tailored oxygen sorbent andmodular ASU that can readily integrate with a 1- to 5-MW modularcoal gasification system that reduces energy consumption by morethan 30% compared to state-of-the-art ASUs; and demonstration ofthe sorbent and REM-ASU system to validate its robustness andperformance.

• Developed (LaxSr1-x)CoyFe1-yO3 – CoFe(LSCF-CF) composites with 2.2 to4.2% O2 capacity.

• LSCF-CF OS high activitydemonstrated.

• Designed low temperature SrFeO3-based OS for chemical looping airseparation.

• Demonstrated steam resistantSrFeO3-based OS for 1,000 cycles withminimal degradation.

Research Triangle Institute (RTI) will design, fabricate, andtest a 10- to 20-kg/day modular O2 production system. Theeffort will include optimization and scale-up of the oxygenbinding adsorbent; process studies to form the adsorbentmaterial into structured beds for rapid pressure-swingadsorption (PSA) cycles with low pressure drop, fast masstransfer, and low attrition; cycle development studies tooptimize the PSA process; and development of simulationtools for rapid cycle modeling and numericalevaluation/optimization. In addition, the unit will undergoparametric and long-term testing for at least 1,000 hours.

Pilot Testing of a Modular Oxygen Production System Using Oxygen Binding Adsorbents

Design, fabrication, and testing of a 10- to 20-kg/day modular O2production system.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031527

CONTACTS




PRINCIPAL INVESTIGATOR: Dr. John Carpenter

PARTNERS

DOE Share: $3,000k



If proven successful, the technology could reduce the costof air separation and, therefore, the cost of products fromall oxygen-intensive industries. Producing O2 using theproposed binding materials should cost (depending on theO2 capacity) 30 to 40% less than cryogenic distillation.

• Structured sorbentmodule development.

• Begun initial design ofpilot O2 productionsystem.

• Techno-economic analysisperformed.

The University of South Carolina has been developing amembrane stack and module for air separation and oxygenproduction by scaling up an innovative technology involvingan intermediate-temperature ceramic hollow fibermembrane. The technology is then incorporated into aRadically Engineered Modular Systems (REMS) gasificationskid and supports the oxidant feed of an oxygen-blownREMS gasifier scaled to various ranges.

Modularization of Ceramic Hollow Fiber Membrane Technology for Air Separation

Develop a membrane stack and module for air separation and oxygen production using an intermediate-temperature ceramic hollow fiber membrane.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031473

CONTACTS




PRINCIPAL INVESTIGATOR: Xingjian (Chris) Xue

PARTNERS

DOE Share: $1,539k


Total Award Value: $1,932kSuccessful development of this technology may improve

performance, reliability, and scale-up flexibility, as well asreduce capital and operating costs. These improvementscould have broader impacts on the development of high-performance and durable air-separation technologies foroxygen intensive industries.

• New membrane design with novel architecture, materialsystem, and microstructure.

• Showing reduced capital cost of membrane cell andlower operating cost.

http://www.google.com/url?url=http://sc.edu/toolbox/logos.php&rct=j&frm=1&q=&esrc=s&sa=U&ei=58-yU6bzAdDKsQSi84CQAQ&ved=0CBgQ9QEwAQ&usg=AFQjCNHaaDAB7SEwruqp88UC3XebsJCIng

Pacific Northwest National Laboratory (PNNL) is developing air separationtechnology based on mixed ion-conducting membranes in planararchitecture and stacks, employing doped CeO2 as the ion conductor andLaMnO3 as the electronic conductor supported on low-cost poroussubstrate of MgO-Al2O3 composites. This technology utilizes thedifference in oxygen partial pressures across the membrane in an airseparation unit to drive the separation of oxygen.PNNL is focusing on multiple technological aspects for increasingperformance efficiency and reducing costs of this technology, includingbest use of low-cost materials, planar stack architecture design allowingreliable and low-cost fabrication/processing and stack/seal performance,minimizing interactions between ionic and electronic conducting phasesduring sintering to maximize oxygen permeability in the compositemembranes, and controlling sintering so as to minimize warping andcracking of the planar composite membranes.

Pressure-Driven Oxygen Separation

Development of air separation technology to be utilized in advanced coal-based modular energy systems, making substantial progress toward enabling cost-competitive, coal-based power generation with near-zero emissions.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

FWP-73130

CONTACTS

HQ PROJECT MANAGER:Jai-Woh Kim


FEDERAL PROJECT MANAGER: Venkat Venkataraman

PRINCIPAL INVESTIGATOR: David Reed

PERFORMER

National Laboratory Share: $1,000k


This membrane-based oxygen separation approach is intended to enablesmall-scale, modular air separation units providing 10 to 40 tons of high-purity oxygen to 1- to 5-MWe gasifiers at low cost and high energyefficiency.Because the air separation membrane is of the ion transport type, itprovides extremely high oxygen selectivity. But unlike conventional iontransport membranes that require operating temperatures of 1,450 to1,650°F, PNNL’s membrane is targeted for operation at 1,100 to 1,300°F.At these milder conditions, energy demand for heating input gases islower, and equipment durability should be improved.

• Material properties and interactions of themembrane and support structurecharacterized.

• Fabricated composite structures by tapecasting with controlled microstructures.

• Alternative methods to co-sinter large areaparts with minimal interactions at themembrane/support structure.

• Low-cost manufacturing and materials andachievable oxygen flux are showing goodtechno-economic potential.

Los Alamos National Laboratory (LANL) is developing carbon molecularsieve (CMS) hollow fiber membranes for use in a modular air separationunit (ASU) for high-purity O2 production. A two-stage membrane processis envisioned and will be optimized to achieve O2 purity of up to 95%while minimizing process energy consumption. Core to the proposedwork is development of polybenzimidazole (PBI)-derived CMS hollowfiber membranes having exceptional O2/N2 selectivity and high O2permeance. The PBI-CMS hollow fiber membranes will be obtained viacontrolled pyrolysis of PBI hollow fibers having microstructures tailoredfor gas separations (PBI hollow fiber manufacturing methods recentlydiscovered/patented by the LANL team).Current work is focusing on optimizing the PBI-CMS hollow fibermembrane fabrication protocols, pyrolysis, and process design of themembrane system in context to energy plants and systems.

High Selectivity and High Throughput Carbon Molecular Sieve Hollow Fiber Membrane-Based Modular Air Separation Unit for Producing High-Purity O2


Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

FWP-FE-1049-18-FY19

CONTACTS




PRINCIPAL INVESTIGATOR: Rajinder P. Singh

PERFORMER



Membrane-based ASUs have better energy efficiency than industry-standard cryogenic methods, provided materials having high O2/N2selectivity and high productivity membrane systems based on thesematerials are developed. PBI-CMS membranes have exceptionalseparation performance potential, and when deployed in high packing-density and low-cost hollow fiber membrane modules familiar inindustrial application, should enable energy-efficient high-purity O2production at modular scales.

• Achieved O2/N2 selectivity of 15 in the PBI-CMS hollow fiber membranes (permittingachievement of the target for O2 purityassuming a two-stage membrane process).

• Significant improvement in the O2permeance of the PBI-CMS hollow fibermembranes from 0.05 to 1.8 GPU.

• Promising initial results obtained towardsachieving asymmetric morphologies inhollow fiber fabrication (necessary forindustry deployment).

Idaho National Laboratory (INL) and Argonne National Laboratory aredeveloping a novel type of mixed matrix membrane to be deployed inhollow fiber configuration for modular oxygen production for coal-basedenergy systems. Conventional membrane-based gas separationtechnology faces the general problems of low gas permeability, poorspecies selectivity, and poor durability of the membranes in operatingenvironments. However, the team has found that a mixed matrixmembrane consisting of a base polymer support layer of polysulfone,which incorporates functionalized nanodiamonds (ND) in a compositematrix, both greatly increases the material’s O2 permeability andincreases the material’s durability by reducing plasticization and aging.Multiple points of technological advancement are underway, such asoptimizing surface functionalization of NDs, dispersion of NDs in thematrix, selective and gutter layer fabrication, and membrane systemsprocess design using this novel type of membrane for oxygen production.

Advanced Oxygen Separation from Air Using a Novel Mixed Matrix Membrane


Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

FWP-B000-18-061

CONTACTS




PRINCIPAL INVESTIGATOR: Frederick Stewart

PERFORMER



Membrane-based gas separation processes have advantages in that theycan be readily scaled (including to the modular size ranges for energysystems of interest), reach operating conditions quickly, and respond wellto either surges or slack demand. The INL team is working to makesignificant improvements to hollow fiber membranes for these processes,but without losing the features that make these materials readily andreliably manufacturable. In this way, mature processes for hollow fibermembrane manufacture will not be compromised, thereby de-risking thecommercial deployment of this technology.

• NDs have been shown to improveoxygen membrane permeability by afactor of 150 and to improve membranedurability.

• Improvements have been made inmembrane selective and gutter layers.

• Demonstration of phase inversion ofpolysulfone-ND composites ensuringthat hollow fiber formation can beaccomplished with desirable inducedmorphologies.

PARTNER

Pacific Northwest National Laboratory (PNNL) is developing theMagnetocaloric Oxygen Liquefier System (MOLS) technology in thisproject. MOLS uses magnetization and demagnetization of solids forrefrigeration instead of conventional gas compression and expansion. Theprinciple exploited is that highly reversible, adiabatic heating or coolingoccurs in ferromagnetic materials near their Curie temperatures whenthey are subjected to large (approximately 6 to 7 Tesla) magnetic fieldchanges. MOLS cycles these materials in and out of high magnetic fields,causing them to behave as solid-state refrigerants in a magneticregenerative liquefaction cycle that minimizes the use of mechanical gascompression. MOLS results in liquefied air, which can then be subjectedto conventional cryogenic distillation.Technology development focuses on attaining the temperature reductionover the required range (to a liquid air temperature of 100K) throughidentification and combination of multiple layers of refrigerant materialsin suitable regenerator configurations and advancing superconductingmagnet design and integration with the regenerator.

Magnetocaloric Cryogenic System for High-Efficiency Air Separations


Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

FWP-73143

CONTACTS




PRINCIPAL INVESTIGATOR: Jamie Holladay

PERFORMER



Gas compressors and expanders in cryogenic air separation units (ASUs)are the major cost drivers of conventional air separation. MOLS almostentirely eliminate the need for conventional gas compression incryogenic-based air separation. Preliminary cost analysis indicates thatMOLS will be no more or even less expensive than the conventionalliquefaction technologies used in cryogenic ASUs. Moreover, MOLS ishighly modular, providing good cost performance for smaller amounts ofoxygen production at which conventional cryogenic ASUs would havepoor cost performance.

• Established design basis for MOLS activemagnetic regenerative liquefier.

• Designed multi-layer magnetic regenerator.• Modeled design of new 6.5 Tesla

superconducting magnet.• Achieved cooling to 135K using multi-layer

regenerators.• Demonstrated liquefaction of methane

using MOLS.

Oak Ridge National Laboratory (ORNL) is tackling the challenge ofobtaining non-intrusive measurements of coal gasification and pyrolysisreactions occurring inside high-temperature and high-pressure reactorvessels. Accurate in situ measurements are key pieces of crucial dataneeded by multiphase flow simulation/models (e.g., Multiphase Flowwith Interphase eXchanges [MFiX]) for tuning and validation. In turn,these simulations are critical to designing the next-generation reactorsneeded for advanced new energy systems.ORNL’s innovative measurement approach involves neutron imaging. Thisleverages the properties of neutrons, which interact strongly withhydrogen but weakly with metals, giving the ability to view coal pyrolysisand gasification in situ (i.e., right through the walls of reactor vessels).ORNL is applying unique science capabilities in this work: neutronimaging at the High-Flux Isotope Reactor (HFIR), and Spallation NeutronSource (SNS) facilities are using SpaciMS (a technique developed by ORNLfor capillary-based measurement of reactants and products in processconditions).

Experimental Validation of Coal Gasification with Neutron Imaging

In the area of research for control of chemical reactions in increasingly modular and intrinsically efficient reactors, allowing for smaller reactors and streamlined process systems for gasification of coal into syngas, syngas cleanup, and syngas conversion.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

FWP-FEAB325

CONTACTS




PRINCIPAL INVESTIGATOR: James E. Parks II

PERFORMER



This work is resulting in new scientific methods for neutron-basedcharacterization of coal gasification. This will enable robust,experimentally validated models and designs for modular coal gasifiers.There is also the benefit of strong collaboration between ORNL and theNational Energy Technology Laboratory (NETL) in these research areas.

• Neutron experiments for pre-pyrolysis of multiple coal ranks anddynamic in situ pyrolysis of poplar and lignite accomplishedsuccessfully.

• Groundwork established to continue to imaging of dynamic in situpyrolysis of higher coal ranks and dynamic in situ gasification.

Advanced Gasifier DesignLeveraging NETL’s multiphase computational modeling expertise in reactor design problems, and utilizing MFiX and other key software tools.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

NETL FWP 1022405, Task 3

CONTACTS



FEDERAL PROJECT MANAGER: William Rogers

PRINCIPAL INVESTIGATOR: William Rogers

DOE Share: $5,461k


This work emphasizes the application of the National Energy TechnologyLaboratory’s (NETL) multiphase computational fluid dynamics (CFD)software (Multiphase Flow with Interphase eXchanges [MFiX]) and NETL’sOptimization Toolset and other key software tools to supportdevelopment of modular gasification technology. These advancedsoftware tools and the Office of Fossil Energy (FE)/NETL’s supercomputingfacilities will be used to investigate different reactor configurations todetermine optimal modular gasifier designs. Advanced gasificationreactors will allow precise manipulation of different feedstock and bedmaterial particles and the reactant and product gases in fluidized bedgasification reactors of interest to the program.Computational modeling tools are also to be used to design, analyze, andoptimize key components of modular gasifier systems, including oxygenseparation and product gas cleanup systems.

Through this research and development (R&D), NETL is providing anadvanced capability to use performance predictions from multiphase flowCFD simulation to optimize reactor performance. In contrast toproprietary commercial CFD software, the MFiX suite and associatedtoolsets are open-source codes freely available to stakeholders, includingindustry and universities. This enables deployment of the tools on a widerange of problems and widespread collaboration in the user community.Feedback from the user base helps focus troubleshooting and furthercode development efforts.

PERFORMER

• Simulations of moving bed gasifier at theSotacarbo test facility for Alaskan Usibelli coal,validating proposed chemical kineticmechanism and reaction rate parameters.

• Capabilities of Optimization Toolsetdemonstrated by CFD simulations of a fluidizedbed gasifier, identifying optimum operatingconditions yielding syngas product ratio of 2:1H2 to CO.

The University of Alaska Fairbanks will provide detailedengineering, design, and analysis to produce a front-endengineering and design (FEED) study for a modular designof an air-blown fixed-bed gasifier with gas cleanup to poweran existing diesel engine generator. The FEED study willinclude technologies for lowering sulfur oxide (SOX) andnitrogen oxide (NOX) emissions to allow for operating thediesel engine on syngas. A model of the generating andtransmission system at Golden Valley Electric Associationwill be created to evaluate the potential impact that asyngas/engine generation plant will have on the localelectrical grid.

Making Coal Relevant for Small-Scale Applications: Modular Gasification for Syngas/EngineCHP Applications in Challenging Environments

Modular gasification producing syngas to fuel reciprocating engines in combined heat and power application.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031601

CONTACTS




PRINCIPAL INVESTIGATOR: Brent Sheets

PARTNERS

DOE Share: $1,163k



This effort supports the design, construction, and operationof large test facilities for transformational coal technologiesaimed at enabling step-change improvements in coal-powered system performance, efficiency, and cost ofelectricity. Pilots supported by the U.S. Department ofEnergy (DOE) will be used to assess the scalability andcommercial potential of transformational coal technologies,helping mitigate risk and aiding in commercial adoption.

• Development of FEED study fora modular air-blown gasifierdesign is underway.

Advanced Manufacturing Technologies and Materials for Gasification

Identify construction materials and manufacturing technologies to build small-scale computer-modeled ARS gasification modules.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:


CONTACTS



FEDERAL PROJECT MANAGER: Jonathan Lekse

PRINCIPAL INVESTIGATOR: Omer Dogan

DOE Share: $1,375k


The objective of this effort is to identify materials of constructionand manufacturing technologies to build small-scale computer-modeled gasification modules that will meet system performancerequirement in laboratory studies (temperatures up to 1,200°C,coal as the primary carbon feedstock, an initial targeted materialthroughput of one ton/hour, and an initial service life of 500hours). Samples of both reaction chamber and carbon feedstockmaterials, and the reaction system products/byproducts, will beevaluated to validate and modify computer models that are beingleveraged to aid in synergistic research and development (R&D)across tasks.

Advances in technology will allow construction of gasificationsystems using effective combinations of metals (to confine theprocess and support the reaction chamber structure) andrefractory ceramics (to withstand and confine the harsh high-temperature reaction chamber environment against wear andcorrosion). This will help enable systems with low costs ofconstruction, predictable system performance and service life, andthat will operate efficiently and cost-effectively.

Impact of raw material selection. Particle coherency in functionally graded layers.

PERFORMER

The purpose of this project is to develop a novel, cost-effective, radically engineered modular gasifier. This gasifierwould have applications to 1- to 5-MW energy-conversionsystems, such as combined heat and power (CHP). Thepressurized oxygen-blown gasifier will use a simple, small-scale modular design and produce negligible amounts oftar. The gasifier will also be highly flexible to optimize fuelthroughput and thermal efficiency, manipulate coalconversion, and produce syngas of a desired composition.

Small-Scaled Engineered High Flexibility Gasifier

Development of a novel, 1- to 5-MW modular gasifier.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031531

CONTACTS




PRINCIPAL INVESTIGATOR: Mikhail Granovskiy

PARTNERS

DOE Share: $1,700k



Potential reduction of the cost of coal conversion via anoptimized, factory-built modular system to allow scale-upvia modular expansion and deployment at remote sites.

• Modeling efforts and flexibleinput capability for oxygen andsteam have confirmed the abilityto manipulate temperaturedistribution within gasifier.

• Gasifier design and constructionunderway.

The philosophy driving Mainstream Engineering Corporation’s project isthat utilization of coal wastes, biomass, and municipal solid waste (MSW)as mixed feedstock in modular gasification would advantageously reduceproblematic waste streams while providing a route to liquid and gaseousfuel products with low pollutant emissions. Entrained flow gasification(EFG) is a favorable choice for high-quality syngas for the synthesis offuels. However, these gasifiers face the problem of effectively feedinglarge biomass and waste particles. A solution to the feeding problems isto use a low-temperature pyrolysis reactor for torrefaction of biomassmixtures, creating a feedstock similar to coal and capable of being grounddown, mixed with the coal feed, and fed into the gasifier.Current project scope involves gasification testing of torrefied MSW andwaste coal in a pilot-scale EFG, enabling characterization of preparation,feeding, and slagging behavior. Also, continuous torrefaction reactortechnology is to be developed.

Conversion of Coal Wastes and Municipal Solids Mixtures by Pyrolysis Torrefaction and Entrained Flow Gasification

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

SC0018580

CONTACTS

HQ PROJECT MANAGER:Regis Conrad


FEDERAL PROJECT MANAGER: Steven Markovich

PRINCIPAL INVESTIGATOR: Nicholas Schwartz

PERFORMER

DOE Share: $1,150k

Performer Share: N/A


• Provides a way to utilize waste coal plus other opportunity fuels,eliminating waste streams while yielding valuable energy products withminimized pollutant emissions.

• Helps enable modular gasification technology suitable for strategicdeployment in coal preparation locations, military installations, etc.

• Advancing towards coal waste plus MSW processing for power plants,enabling reduction in capital, operating, and maintenance costs forco-firing biomass and mixed waste with coal.

• Sourced representative MSW frompredominate waste coal regions in UnitedStates.

• Torrefied MSW at optimal conditions withpilot-scale torrefier.

• Pilot-scale EFG testing at Energy andEnvironment Research Center (EERC) withtorrefied MSW and waste coal (ongoing).

• Demonstrated proper slagging of MSW andwaste coal.

• Completed preliminary design of continuousbench-scale torrefaction reactor.


Microwave Reactions for Gasification

Develop microwave technology for coal gasification by measuring the impact of different variables for microwave conditions on conversion and product yields for coal gasification.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:


CONTACTS



FEDERAL PROJECT MANAGER: Mark Smith

PRINCIPAL INVESTIGATOR: Mark Smith

DOE Share: $2,356k


The National Energy Technology Laboratory (NETL) is focused on amicrowave-based concept for coal gasification to syngas, which couldresult in the co-production of energy and value-added chemicals atrelatively low temperatures. The underlying objective of using amicrowave-enhanced process is twofold. First, the use of microwavesprovides selective heating of the targeted sites of a material, therebyenhancing the activity without increasing the temperature of thesurrounding bulk gas, inert catalyst support, and reactor systemcomponents. Therefore, any reaction can be initiated at the active sites or“hot spots” while the bulk temperature might be significantly lower,enhancing the selectivity limited by thermodynamics. Second, themicrowaves play the role of a promoter. The energy delivered by amicrowave field is not sufficient to break or form chemical bonds.However, the microwave field can induce the polarization of reactingmolecules and/or catalyst surface site resulting in a weakened bond thatcan be more easily broken.

Chemical conversion can be enhanced by applying radiofrequency/microwave fields and/or plasmas to the catalytic reaction zone.The high-frequency microwave fields can selectively stimulate activemetal sites on catalysts through dielectric and magnetic interactionswithout increasing the bulk gas temperature and solid medium. Theseconditions can result in product yields that are significantly higher thanpredicted by thermodynamics, which can provide savings in both energyand feed costs.

• Completed proof-of-concept experiments forconversion of residual carbon in ash fromthermal gasifier.

• Developed high-temperature testing cell fordielectric characterization of samples underdifferent gas and operating conditions.

• Design, construction, and operation of newVariable Frequency Microwave Reactor (B14 –Reaction Analysis and Chemical Transformation[ReACT] Lab).

PERFORMER

Research Triangle Institute (RTI) is developing modulardesigns for the cleanup of warm syngas with reduced costs,emissions, and improved thermal efficiency, enabling 1- to5-MW Radically Engineered Modular Systems (REMS)-basedplants to be cost-competitive with large, state-of-the-artcommercial plants using abundant domestic coal reserves.

Advanced Syngas Cleanup for Radically Engineered Modular Systems (REMS)

Develop modular designs for the cleanup of warm syngas by addressing key knowledge gaps.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031522

CONTACTS




PRINCIPAL INVESTIGATOR: Dr. Atish Kataria

PARTNERS

DOE Share: $1,599k


Total Award Value: $1,999kIf proven successful, RTI’s designs for modular warm syngas

cleanup will provide a pathway to reduce the cost andincrease the efficiency of producing syngas from coal ormixtures of coal. Additional benefits include increased plantavailability, reduced capital costs and cost of energyproduction, reduced development time and cost, reducedgreenhouse gas emissions, and leveraging technicalbreakthroughs with commercial technologies.

• Completed testing of low-sulfursyngas with excellent sorbentperformance.

• Completed acquiring hydrodynamicdata for the sorbent at key regionswithin the fluid-bed reactor systemusing the existing cold-flow unit.

• Received pilot-scale wet cake fromsupplier for testing.

The University of Kentucky Research Foundation will test astaged opposed multi-burner (OMB) gasifier for a scaled-down version of a commercial gasification technology thatutilizes coal slurry as a feed for high-temperaturegasification. This project has the potential for small-scalemodularization with standardized burners.

Staged Opposed Multi-Burner (OMB) for Modular Gasifier/Burner

Testing of a staged OMB for use in modular applications.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0031506

CONTACTS




PRINCIPAL INVESTIGATOR: Dr. Rodney Andrews

PARTNERS

DOE Share: $1,612k


Total Award Value: $2,016kPotential enhancement of a viable technology that may (1)

better realize the full potential of abundant fossil energyresources, such as coal, in an environmentally sound andsecure manner; (2) achieve modularized gasification in lieuof commercial experience at low risk; and (3) satisfy theinterests of end users at low cost.

• OMB testing at multipleconditions undertaken.

• Burner testing underway.• Fuel flexibility testing

ongoing.

The project team will design a gasification reactor usingcomputational fluid dynamics (CFD) and kinetic modeling toachieve optimum carbon dioxide (CO2) removal and hydrogenrecovery. TDA will perform system design and sorbent production,working in conjunction with GTI in the design and fabrication of aslipstream test unit. University of California-Irvine and Indigo PowerSystems will conduct the process modeling and design, and willcarryout the system and economic analyses. Praxair will supportthe field tests at the Praxair Facility in Tonawanda, New York.

Integrated Water-Gas Shift (WGS)/Pre-Combustion Carbon Capture Process

Develop an integrated WGS pre-combustion CO2 capture technology to eliminate CO2 emissions from integrated gasification combined cycle (IGCC) power plants and coal-to-liquid plants.

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

DE-FE0023684

CONTACTS




PRINCIPAL INVESTIGATOR: Gokhan Alptekin

PARTNERS

DOE Share: $4,507k

Performer Share: $1,126k


Develop new CO2 capture technology for use in integratedgasification combined cycle (IGCC) and coal-to-liquid (CTL) plantsthat run on a wide range of coals (bituminous to low-rank) andpetcoke. The integrated water-gas shift (WGS) pre-combustion CO2control system achieves high CO2 capacity and removal efficiency(>90%) at temperatures well above syngas dew point for allcommercial gasifiers. High-temperature CO2 removal capabilityeliminates the need to condense the steam in the gas andmaximizes the mass flow through the gas turbine, therebyincreasing the efficiency of the power cycle. This technology willprovide U.S. developers with an effective carbon capture systemthat is much more efficient than conventional low-temperaturescrubbers.

• Completed production of the sorbentneeded for field testing.

• Completed evaluation of the singlereactor and new injector.

• Continued modifications to existingfixed-bed test rig for life-cycle testing.

Coal-derived syngas normally contains sulfur contaminants, mainly inthe form of hydrogen sulfide, which are conventionally removed priorto downstream usage of the syngas. However, conventional cleanupprocesses for acid gas removal may not capture certain tracecontaminants, the removal of which may be demanded by morestringent regulations or by requirements of certain downstreamprocesses. TDA Research, Inc. is developing a low-cost, high-capacitysorbent that can remove ammonia (NH3), hydrogen cyanide (HCN), andtrace metal contaminants (such as mercury [Hg], arsenic, andselenium) from coal- and coal/biomass-derived syngas in a singleprocess step. Work is establishing operating parameters in multiple-cycle experiments and testing sorbent durability/lifetime.

Warm-Gas Multi-Contaminant Removal System

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

SC0008243

CONTACTS




PRINCIPAL INVESTIGATOR: Gokhan Alptekin

PERFORMER

DOE Share: $2,150k



Unlike commercially available gas clean-up technologies, the TDAmulti-contaminant control system operates above the dew point of thesyngas (500°F). With this technology, the syngas would not have to becooled in order to remove the contaminants, thus improving thethermal efficiency of the process.Overall, this technology will benefit production of high-hydrogen, low-methane, ultraclean syngas, which can be versatilely used for powerproduction with carbon dioxide (CO2) capture, fuels or chemicalsproduction, and polygeneration applications.

• Slipstream testing demonstrating continuousremoval of NH3 and Hg using coal derivedsyngas at the National Carbon Capture Center(NCCC).

• Techno-economic analysis estimate for cost ofremoving NH3, Hg, arsine (AsH3), and HCNcontaminants is ~$3.7 MM per year ($10.1MM with annualized capital cost) for a designbasis 550-MW integrated gasificationcombined cycle (IGCC) plant.


TDA Research, Inc. is developing sour-shift catalysts to enable highercarbon monoxide (CO) water-gas shift (WGS) conversions than possiblewith currently available commercial catalysts. The new catalysts are beingdeveloped to operate with reasonably fast kinetics at lower temperatureswhere the WGS equilibrium is more favorable. The catalysts are alsobeing developed to be resistant specifically to poisons found inbiomass/coal-derived syngas.As improved promoted Co-Mo/Al2O3-type sour WGS catalysts areformulated and prepared, their performance is being assessed in testingcampaigns. Exactly how poisons affect the new WGS catalysts whenpresent in syngas derived from coal/biomass combinations is animportant testing focus. TDA is having larger-scale testing performed atthe Energy and Environmental Research Center (EERC) in North Dakota,where EERC’s pressurized fluidized bed gasifier is used to generate syngasfor testing of the TDA sour WGS catalysts in shift reactors (9 liter volume).

Poison Resistant Water-Gas Shift Catalysts for Biomass and Coal Gasification

Overview

Recent Results

Benefits

QUICK FACTS

PROJECT BUDGET

AWARD NUMBER:

SC0004378

CONTACTS




PRINCIPAL INVESTIGATOR: Girish Srinivas

PERFORMER/PARTNER

DOE Share: $2,058k



Extensive reserves of cheap coal in the United States, combined withsubstantial amounts of agricultural residues, provide the opportunity forcombined coal/biomass gasification. Gasification enables syngasproduction; syngas can be shifted and converted to liquid transportationfuels via Fischer-Tropsch synthesis or other processes, while hydrogencan be recovered for synthesis of other value-added chemicals andproducts. Using the TDA innovative WGS catalysts would enable cheapersyngas production from coal/biomass blends; carbon footprint is loweredwith biomass in the mix, and with capture, negative greenhouse gasemissions are possible.

• Second catalyst testing campaign run (high-Tshift reactor online 323 hours, low-T shiftreactor online 284 hours); coal-derived syngasused for part of campaign.

• Air-cooled heat exchanger between shiftreactors found to enable better low-T shiftreactor temperature control.

• Shift reactors operated at targeted temperatures(first stage 600°F, second 446°F).

• Surface area and elemental analyses of usedcatalyst performed to assess catalyst durability.


netl gasification systems...gasifier designs to increase syngas heating values, reduce reactor size,...

Documents