A Higgyh Efficiency Inertial CO2 Extraction System (ICES) · Fluegas Supersonic expansion T=330K...

A premier aerospace and defense company

A High Efficiency g yInertial CO2 Extraction System

(ICES)(ICES)

Dr. Anthony Castrogiovanni, Dr. Vladimir Balepin,Andrew Robertson, and Bon Calayag

Presented at the

NETL CO Capture Technology MeetingNETL CO2 Capture Technology MeetingPittsburgh, PAJuly 11, 2012

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Company Backgrounds

• ATK is a leading aerospace & defense contractor• ACENT is a small business dedicated to applying expertise in aerospace and defense to clean energy challenges

• Founded in 2007, ACENT is developing

• ATK is a leading aerospace & defense contractor• ATK GASL in Ronkonkoma, NY operates the ATK Center for Energy and Aerospace Innovation

• Expertise and research interests include :• Aerospace propulsion Founded in 2007, ACENT is developing

technologies in CO2 capture, algal biomass, hydrogen vehicles, and enhanced oil recovery

• Aerospace propulsion• Carbon capture• Hydrogen fueled vehicles• Clean coal technologies• Oil recovery solutions• Oil recovery solutions

• ICES utilizes some methods developed under

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a DOE SBIR with ACENT


Project Overview

Funding Summary:ARPA e: $ 2 693 KARPA-e: $ 2,693 KATK and ACENT Cost Share: $ 632 KNYSERDA (New York State) $ 200 K ( ) $TOTAL $ 3,525 K

Project Performance Dates:Phase 1: July 2010 – March 2011 (completed)Ph 2 J l 2011 J 2013 ( i )Phase 2: July 2011 – June 2013 (ongoing)

Project Participants:Project Participants:Alliant Techsystems (ATK)ACENT Laboratories LLC

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WorleyParsons


Overall Project Objectives

• Demonstrate proof-of-concept of aero-thermodynamic CO condensation and separationCO2 condensation and separation

• Develop and benchmark analysis tools with experimental d t t bldata to enable:

• Scaling of demo system to power plant size

• Projection of economics in terms of COE and parasitic loads

• Provide basis for next-phase slip-stream testing with real flue gas

• Minimize flue gas pressurization requirements

• Maximize CO2 capture (>90% goal)

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Maximize CO2 capture ( 90% goal)


ICES Technology Fundamentals

• Pulverized coal power plant flue gas contains ~16% CO2 in gaseous form at low pressure

• In ICES we compress flue gas to a moderate level andgas to a moderate level and use the low temperature created by supersonic expansion to freeze theexpansion to freeze the CO2 in the flow

• ICES uses turning induced in the flow to inertiallyseparate the solid particles from the gas stream

• We capture and collect the CO2 (as dry ice) and then process using a self-pressurization system exploiting power plant waste heat

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system exploiting power plant waste heat


ICES on a P-T Diagram – Supersonic Expansion

12.01000

Isentropic Expansion of 16% CO2 in Nitrogen Relative to Phase Diagram of CO2

Liquid Phase

10.0100

Triple Point

Region of incipient

8.010

mbe

r

[psia]

pcondensation Gas Phase

4.0

6.0

0.1

1

Mach Num

Pressure [

Evolution of Partial Pressure of CO2 during Isentropic Expansion in Supersonic Nozzle(p0=30psia, T0=520ºR)

Solid Phase

2.00.01

(p0 30psia, T0 520 R)

0.00.001

0 100 200 300 400 500 600

T [R]

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Temperature [R]


ICES Integration in PC Plant

18Flue Gas C l

Flue Gas Compressor

TBD Coolant

1719

22

Cooler Compressor

ICES Unit

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22ICES Unit

Water20

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ICES System Schematic

Compressor/HEX16

T 330K

18 19

22

HEX

Solid CO2

Capture DuctFluegas

Supersonic expansion

T=330KP=1.05 atm15% CO2

Subsonic diffusion

HEX

Cyclone separator (slip gas + CO2)

Flue gas from FGD T=300K

P=1.03 atm T=300KP=2.0 atm

T=400KP=1 atm<1.5% CO2

X

X

X X

T=298KP 150 t

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CO accumulation

P=150 atm>99.5% CO2

CO2 accumulation & self pressurization system

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X

Water Drain20


ICES Economic Impact

• ICES operating costs are driven by flue gas pre-compressionP f t P /P• Pressure recovery factor = P22/P19

• Low CapEx/OpEx combined with low power consumption result in a

j t d t f l t i it i fprojected cost of electricity increase for CO2 capture just over 1/3 that of the amine process

• Compression to 2,250 psi from low grade waste heat (constant volume heat addition to solid). Cost is limited t CAPEX + t dito CAPEX + energy to move media.

Metric ICES AmineCOE % increase 35% 81%Parasitic Load 12.5% 21.5%

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Cost per ton of CO2 avoided US$ 27 US$ 68


Energy Consumption

Process Minimum Energy [kJ/kg CO2]

ICES[kJ/kg CO2]

Amine[kJ/kg CO2]

S ti 175 683*Separation -175 -683* -CO2 Compression -247 ~68** -Total -422 -751 -1,506Total 422 751 1,506

* Pre-compression of flue gas to 2 bar (absolute)** + Approximately 760 kJ/kg of low grade waste heat used to compress CO2from solid phase to 2 250psiafrom solid phase to 2,250psia

Fixed volume at ambient

~760 kJ/kg latent sensible heat

Supercritical CO2

pressure partially filled

with solid CO2 at 200 ºF

Initial Volume % filled with solid

Pressure at 70ºF [psia]

2

-200 ºF filled with solid 70 F [psia]

60% 3,00065% 6,000

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Compression energy is nearly “economically free” but it is not “thermodynamically free” i.e. this energy would otherwise be wasted


ICES Plant Integration and Footprint

An ICES system sized for 545MW-equivalent flue gas contains twelve 60” ICES units (flue gas compression not shown)

L= 183 ftL= 183 ftW= 60 ftH = 70ft

ICES is projected to have a significantly smaller footprint and complexity compared to competing CO2 capture technologies and hence significantly

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compared to competing CO2 capture technologies and hence significantly lower capital and maintenance costs


Key Advantages of ICES over other options

• No moving parts (after start)

N h i l / dditi th bl di• No chemicals/additives or other consumable media

• No refrigeration expense – low temperatures from supersonic expansionexpansion

• Inexpensive construction (concrete, sheet metal)

• Small footprint• Small footprint

• ICES units in test are equivalent to 0.3-0.6 MW slip stream

• The latest unit (0 3 MW) is 24” x 24” x 3”• The latest unit (0.3 MW) is 24 x 24 x 3

• Small size enables distributed deployment for other process applications in the petroleum and chemical industriespp p

• Availability of “cold sink” in solid CO2 accumulated

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ICES Development Challenges

• Development of optimized supersonic contour to maximize particle size/migration and minimize pressuremaximize particle size/migration and minimize pressure losses

• Minimization of “slip gas” that is removed with solid CO2

• CO2 purity unknowns - other flue gas impurities thatCO2 purity unknowns - other flue gas impurities that condense will be removed with the CO2

S lid CO t/ lf i ti• Solid CO2 management/self pressurization

• This really is rocket science….but once the design is y gcomplete, it is easy and inexpensive to build and operate

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Project Status – Phase 1

• Phase 1 and early Phase 2 efforts focused on an axisymmetric system with swirl

ICES test bench

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Axisymmetric System Results

Phase 1 data showed good CO2 condensation and apparent, but erratic migration due to unsteady and separated flowerratic migration due to unsteady and separated flow

Outer (glass) wall)

CenterbodySolid CO2

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We recently changed to a 2D version of ICES

• Better aerodynamic performance (lowerperformance (lower losses)

• Easier to fabricate d t t

Aluminum plenum chamber and throat

Aluminum plate reinforces plenum chamber

and test• No swirl vanes to

induce Clear acrylic sidewallsturbulence/wake

effects• Simpler capture duct

Clear acrylic sidewallsSupersonic flowpath

components made on 3D printer (ABS)

without swirlVacuum interface flange (steel)

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Gen5 Test Article Design – ATK Installation

24” Vacuum Pipe

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Test Data Comparison to CFD – Static Pressure

0.45

0.5

Test Data - Top SurfacesT t D t B tt S f

0.35

0.4

cham

ber)

Test Data -BottomSurfacesCFD Simulation - Top SurfacesCFD Simulation - Bottom SurfacesMach 1 9

0 25

0.3

tion

(Ps/

Pc Mach 1.9Mach 2.1Mach 2.75

0 15

0.2

0.25

ress

ure

Rat

0.1

0.15

Stat

ic P

r

Nucleation Begins

0

0.05

-5 0 5 10 15 20 25 30

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X Position in Rig Coordinates


Laser Particle Imaging Diagnostic

Test Article

High Speed HD Laser Sheet Image cameraImage

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Nd:YAG Laser


1, 10, and 100 Micron Particle Trajectories

1 μm1 μm

10 μm

100 μm100 μm

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At 10 microns+ particles separate and coalesce allowing for a slender capture slot


Three modes in typical ICES test

CO2 migration toward lower wall evident

1) Air flow only

wall evident

2) 30 psi, 20% CO2

Optical and CO2 sampling results show condensation as e pected b t less than desired migration e ident Particle si e

3) 30 psi, 10% CO2

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expected, but less than desired migration evident. Particle size does not appear large enough in these tests


Condensate Particle Size Control

• Classical nucleation theory provides basis for predicting critical condensate cluster size and subsequent growth rate:

• Both are strong function of the saturation ratio (S) = partial pressure of vapor/saturation pressure (pv/ps)

0 8

1

1.2

Diameter

• Maximum initial cluster size near S=1• Desirable to grow these clusters versus

0 2

0.4

0.6

0.8

s Critical Cluster D nucleating new ones at higher S

• Nozzle contour shape needs to be optimized for this purpose

‐0.4

‐0.2

0

0.2

Dim

ension

less • Need to further increase residence time

of flow in this critical region• Increasing scale toward power plant

i ill h l

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0.900 0.950 1.000 1.050 1.100

Saturation Ratio

size will help


Current Plans

• Remaining portion of Phase 2

I ti t fl di ith lid CO ( lf t d) d th• Investigate flow seeding with solid CO2 (self generated) and other media to promote large particle formation (ongoing)

• Update contour to further optimize particle sizeUpdate contour to further optimize particle size

• Integration of capture duct to remove CO2

• Integration of diffuser to return flow to atmospheric pressure with• Integration of diffuser to return flow to atmospheric pressure with minimal losses

• “Phase 3”

• Ideal next step desired is a slip stream test, e.g. at the National Carbon Capture Center (NCCC)

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Accomplishments to date

• Three ICES configurations have been developed and tested to datetested to date

• Demonstrated clean nozzle flow with low apparent losses (to be verified with later diffuser tests)

• Demonstrated supersonic condensation with someDemonstrated supersonic condensation with some migration

Pl i l t i ti l i t hi d i d• Plans in place to increase particle size to achieve desired migration performance

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Acknowledgements

ARPA E:

Dr. Karma Sawyer, Dr. Scott Litzelman, Dr. Daniel Matuszak, Dr. Mark Hartneyy , , , y

NYSERDA:

Dr. Barry Liebowitzy

ATK & ACENT Labs:

Dr. Pat Sforza, Troy Custodio, Vincenzo Verrelli, Skip Day, Dean Feola, Ed Mihalik, Florin Girlea, Kirk Featherstone, Fred Gregory, Randy Voland

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BACKUP

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Schematic of Condensation Process

S = ps / pv , where pv is the partial pressure of the vapor and ps is the vapor saturation pressure at the temperature of the system.

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A Higgyh Efficiency Inertial CO2 Extraction System (ICES) · Fluegas Supersonic expansion T=330K...

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