Ion Transport Membrane (ITM) Technology for Lower-Cost ... · e turbomachinery system ... 2 line or...
Transcript of Ion Transport Membrane (ITM) Technology for Lower-Cost ... · e turbomachinery system ... 2 line or...
Ion Transport Membrane (ITM) Technology for Lower-Cost Oxygen Production
Rob Steele – EPRI([email protected])
Phil Armstrong - Air Products and Chemicals Inc.
Arun Bose – DOE NETL
Gasification Technologies ConferenceWashington, D.C.November 3, 2010
2© 2010 Electric Power Research Institute, Inc. All rights reserved.
Project Overview and Update
• A ceramic membrane to separate oxygen from air• A Phase 3 U.S. DOE Cooperative Agreement - to develop the ITM
Oxygen technology at the intermediate scale though 2013– U.S. DOE NETL, Air Products (AP), EPRI, and others– Planned Intermediate-Scale Test Unit (ISTU) 100 ton-O2/day
integrated with 5–15 MWe turbomachinery system
• A Phase 4 DOE award, $71.7 million, to accelerate – Development of ITM module fabrication scale-up – 2000 ton-O2/day pre-commercial scale facility
(110MWe oxycoal or 250MWe IGCC)• EPRI formed seven member power industry
collaboration in 2009 – Additional members are welcome to join
3© 2010 Electric Power Research Institute, Inc. All rights reserved.
ITM Oxygen Membranes
• Single-stage high purity oxygen • Extremely selective and very fast
transport for oxygen• Very compact
0.5 ton/day module
Porous membrane support
Dense, slottedbackbone
Dense membrane
Hot Compressed Air
High Purity Oxygen Product
Oxygen flowing from air through dense membrane
One Membrane in Module
SpacerImages courtesy Air Products. © Air Products. All rights reserved.
800-900oC (1500-1650oF)
14+ bara (200+ psia)
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ITM Oxygen – Wafers and Module Scaled-up to Commercial Size
0.5 ton/day StackProgression to
commercial size wafers
1.0 ton/day Stack
Images courtesy Air Products. © Air Products. All rights reserved.
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ITM Oxygen Process
ITM Oxygen ProcessAmbient Air
99.5% OxygenFuel
Cooling Water
Nitrogen
Flue Gas to CO2 Purification
Electric Power, Steam
Design options for ITM Oxygen process:– Power co-production– Minimum fuel consumption– Minimum CO2 emissions
Images courtesy Air Products. © Air Products. All rights reserved.
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Expansion of Ceramic Processing Infrastructure at Ceramatec, Inc. (Salt Lake City, Utah, US)
Continuous Tapecaster
Slide courtesy Air Products. © Air Products. 2009. All rights reserved. Modified with permission.
High Speed Laser Cutter
Lamination Press
Sintering Furnace
•New equipment in operation
•All wafers for planned 100 ton/day test
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Ceramic Manufacturing Process at CeramatecContinues to Improve and Scale-up
• Large-scale wafer sintering kiln for use in current Phase 3• Capacity: > 25 ton/day per load• Currently: Undergoing qualification trials
Slide courtesy Air Products. © Air Products. 2009. All rights reserved. Modified with permission.
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Project progress to date:– Initial testing of 0.5 ton/day
modules started in 2006– Over 600 days of cumulative
operation in multiple runs– Initial testing of 1.0 ton/day
modules began in February 2010
© Air Products. All rights reserved. Modified with permission.
Subscale Engineering Prototype
© Air Products. All rights reserved. Modified with permission.
© Air Products. All rights reserved. Modified with permission.
0.5 ton/day 1.0 ton/day
Multiple Visits to the Subscale Engineering Prototype (SEP) Site
9© 2010 Electric Power Research Institute, Inc. All rights reserved.
Intermediate-Scale Test Unit (ISTU) Block Flow Diagram – 100 ton/day Oxygen
Air TSA
Com-bustor
Fuel
HotGas
Expander
Fuel
Combustion Air
FiredHeater
ITM
Oxygen
Exhaust
Fanfuel line or “hot” equipmentO2 line or equipment
main “air” circuit
“ambient” temperature equipment
– Design features of IGCC and Oxycombustion– Front-End Engineering Design completed– Project execution underway
10© 2010 Electric Power Research Institute, Inc. All rights reserved.
Advanced Gas Turbines
• Firing Temperature Evolution of Gas Turbines– F-Class GT: ~2500°F [1370°C] (GE 7F and Siemens
5000F)– G/H-Class GT: ~2600°F [1430°C] (GE, Siemens, MHI)– J-Class GT: ~2700°F [1480°C] (MHI)
• Increased air extraction
• Higher output
• Higher net plant efficiency
U08-102701 Image provided by Siemens. Used with permission. All rights reserved.
11© 2010 Electric Power Research Institute, Inc. All rights reserved.
Advanced IGCC with CCS Process Flow Diagram: IGCC w/ ITM, G-Frame GT w/ CO2 Removal
Syngas Diluent (N2)
ExtractionAir
Coal
OxygenGasification
IslandWater Gas
Shift
Slag
ITM
H2S Acid GasRemoval
Unit
Sulfur Recovery
Unit
Sulfur
CO2 Comp.
CO2To Pipeline
Syngas Conditioning
Air
AcidGas
TailGas
Gas Turbine
Syngas Cooling & Hg Removal
Steam Turbine
Steam
HRSG
CO2 Acid Gas Removal
Unit
Fired Heater
BoostComp.
Sulfur Polishing
12© 2010 Electric Power Research Institute, Inc. All rights reserved.
EPRI Due Diligence (TU Report # 1020202)Cryo ASU vs. ITM in IGCC w/ CCS (G-Frame GT)
Cryo Reference Case ITM Case
Gas Turbine Power 1.00 1.00Steam Turbine Power 1.00 1.02Gross Power 1.00 1.01ASU Auxiliary Power 1.00 0.81Total Auxiliary Power 1.00 0.94Net Power Output 1.00 1.03Thermal Input 1.00 1.01Net Plant Heat Rate, Btu/kWhr Base -230Net Plant Efficiency, HHV Base +0.8% point
• Full air-side integration of GT and ASU• Reduction in Auxiliary Load• Positive ITM results warrant further investigation • Further detailed analyses to be conducted through current project
- 20%
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IGCC Improvement Potential
30
32
34
36
38
40
Net
Pla
nt E
ffici
ency
(%, H
HV
Bas
is)
Base P
lant
+ Full CCS
+ G Fram
e GT (1
)+ IT
M+ C
O2 Slurry
+ A
dv. CCS
Notes:1. G Frame GT case includes full air-side GT-ASU integration2. Efficiency Improvements are cumulative
DOE and EPRI support similar IGCC roadmaps
EPRI Roadmap: Future Potential
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EPRI Tasks
• Plant-wide performance and cost analyses• ITM operating envelope and design• Test unit performance evaluation• Requirements for ITM-based power plants• Formulation of future development activities
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EPRI to Evaluate IGCC with CCS Cases
Cryogenic ASU• F-Class CT• Advanced CT
ITM Oxygen• F-Class CT• Advanced CT
AirComp.
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One ITM-Based Approach to Low-Carbon Oxygen/Power Generation
A portion of the heat from the ITM process is retained in the oxygen
Options for ITM system design:– Power co-production– Minimum fuel consumption– Minimum CO2 emissions
Images courtesy Air Products. © Air Products. All rights reserved.
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Summary of Technical Program Status
• SEP tests conducted in 2010:– 1 ton/day ITM modules– Getter for contaminant control
• Advanced module components and automatic shutoff valve proceeding through qualification – Early tests indicate the designs are very robust
• 100 ton/day ISTU project fully underway – Construction to be complete by Q4 2011
• Significant advances in ceramic processing capability at Ceramatec
• Current oxycombustion study indicates ITM yields significant specific capital cost advantage over cryogenic air separation
• IGCC-CCS study in progress
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ITM Oxygen Development Schedule
5
100
2000
Phase 2
Phase 3, ISTU
500 Phase 4, Large-scale Test**
Commercial Power Demonstration
Cap
acity
(to
n/da
y) O
xyge
n
2000 2005 2010 2015 2020Year On-stream
Commercialization(small plants, <800 TPD)
Commercialization(large plants forclean energy etc., 1000s TPD)
**Pre-commercial scale facility (equivalent 110MWe oxycombustion or 250MWe IGCC)
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Acknowledgment and Disclaimer
Neither Air Products and Chemicals, Inc. nor any of its contractors or subcontractors nor the United States Department of Energy, nor any person acting on behalf of either:1. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights; or2. Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this report. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Department of Energy. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Department of Energy.
AcknowledgmentThis technology development has been supported in part by the U.S. Department of Energy under Contract No. DE-FC26-98FT40343. The U.S. Government reserves for itself and others acting on its behalf a royalty-free, nonexclusive, irrevocable, worldwide license for Governmental purposes to publish, distribute, translate, duplicate, exhibit and perform this copyrighted paper.
Disclaimer
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Together…Shaping the Future of Electricity
Images courtesy Air Products. © Air Products. All rights reserved.
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