Ceramic Membranes forOxygen Production in Vision 21Gasification Systems

VanEric Stein and Ted FosterGasification Technologies 2001San Francisco, CAOctober 10, 2001

2© Air Products and Chemicals, Inc. 2001

Acknowledgments

Gary StiegelArun Bose

Edhi JuwonoGeorge GulkoPradeep ThackerHua-Min HuangTom Leininger

Eli DemetriHenry Faulkner

Art SmithRobin Richards abc

3© Air Products and Chemicals, Inc. 2001

Vision 21 includes ceramicmembranes for low-cost oxygen

CO2 Sequestration

Oxygen Mem brane

Electricity

ProcessHeat/Steam

POWER

FUELS

HydrogenS eparation

Gasification

GasS tream

Cleanup

Fuels/Chemicals

F u e l C e l lF u e l C e l l

L iq u id s C o n v e r s io nL iq u id s C o n v e rs io n

H ig h E f f ic ie n c y T u rb in eH ig h E f f ic ie n c y T u r b in e

C oal

OtherFuels

ITMsITMsITMs

4© Air Products and Chemicals, Inc. 2001

Ion Transport Membranesproduce high-purity oxygen

O2- electrons

compressedair

oxygen

P’

P’’O2

O2

O2- ½O2 + 2e-

½O2 + 2e- O2-

Mixed-conducting ceramic membranes (non-porous)

Typically operate at 800-900 °C

Crystalline structure incorporatesoxygen ion vacancies

Oxygen ions diffuse through vacancies

100% selective for O2

jPPOO

O2

2

2∝

ln

'

''

5© Air Products and Chemicals, Inc. 2001

ITM Oxygen integrates wellwith power generation cycles

AIRAIROXYGENOXYGEN

FUELFUEL

HeatExchange

Ion TransportIon TransportMembraneMembrane

HRSG

STEAMSTEAM

OxygenBlower

ELECTRICELECTRICPOWERPOWER

Oxygen‘Air’

6© Air Products and Chemicals, Inc. 2001

IGCC Study with Texaco

IONTRANSPORTMEMBRANE

COALGRINDING &

SLURRY PREPGASIFICATION

LOWTEMPERATUREGAS COOLING

ACID GASREMOVAL

POWERBLOCK

1 CT, 1 ST &1 HRSG

SULFURRECOVERY

TAIL GASTREATING

SOLIDHANDLING

BLACKWATER

HANDLING

Coal

Extraction Air

Oxygen Depleted Air

HP O

xyge

n

CoalSlurry

RawSyngas

RawSyngas

CleanSyngas

Slag

Wat

er

Sour

Cond

ensa

te

Slag Blowdown

Tail Gas

Off

Gas

StackGas

Air

Acid

GasBlack

Water

Hot Extraction Air

Clea

nSy

ngas

Power

Sulfur

LP Oxygen

WaterInjection

IONTRANSPORTMEMBRANE

COALGRINDING &

SLURRY PREPGASIFICATION

LOWTEMPERATUREGAS COOLING

ACID GASREMOVAL

POWERBLOCK

1 CT, 1 ST &1 HRSG

SULFURRECOVERY

TAIL GASTREATING

SOLIDHANDLING

BLACKWATER

HANDLING

Coal

Extraction Air

Oxygen Depleted Air

HP O

xyge

n

CoalSlurry

RawSyngas

RawSyngas

CleanSyngas

Slag

Wat

er

Sour

Cond

ensa

te

Slag Blowdown

Tail Gas

Off

Gas

StackGas

Air

Acid

GasBlack

Water

Hot Extraction Air

Clea

nSy

ngas

Power

Sulfur

LP Oxygen

WaterInjection

7© Air Products and Chemicals, Inc. 2001

IGCC Study Design Basis

Single-train high-pressure Texaco quenchgasifier (950 psig)

– eastern U.S. coal– raw syngas expander– conventional fuel gas cleaning and SRU

Siemens Westinghouse W501G - 60 Hz (272 MW)100% air / N2 integration of ASU / ITM OxygenHRSG and reheat steam turbine (1800 psig)ISO ambient design conditions

8© Air Products and Chemicals, Inc. 2001

ITM Oxygen shows significantbenefits for IGCC

+7409438IGCC Net Power (MW)

∆ (%)CryoASU

ITMOxygen

9© Air Products and Chemicals, Inc. 2001

ITM Oxygen shows significantbenefits for IGCC

- 37235147Oxygen Power Req’t (kWh/ton)

+7409438IGCC Net Power (MW)

+240.941.8Net IGCC Efficiency (% LHV)

∆ (%)CryoASU

ITMOxygen

10© Air Products and Chemicals, Inc. 2001

ITM Oxygen shows significantbenefits for IGCC

- 37235147Oxygen Power Req’t (kWh/ton)

+7409438IGCC Net Power (MW)

+240.941.8Net IGCC Efficiency (% LHV)

+53,0403,200Oxygen Plant Size (sTPD)

∆ (%)CryoASU

ITMOxygen

11© Air Products and Chemicals, Inc. 2001

ITM Oxygen shows significantbenefits for IGCC

- 37235147Oxygen Power Req’t (kWh/ton)

+7409438IGCC Net Power (MW)

+240.941.8Net IGCC Efficiency (% LHV)

- 3520,13213,000Oxygen Plant Cost ($/sTPD)

+53,0403,200Oxygen Plant Size (sTPD)

∆ (%)CryoASU

ITMOxygen

12© Air Products and Chemicals, Inc. 2001

ITM Oxygen shows significantbenefits for IGCC

- 37235147Oxygen Power Req’t (kWh/ton)

+7409438IGCC Net Power (MW)

+240.941.8Net IGCC Efficiency (% LHV)

- 3520,13213,000Oxygen Plant Cost ($/sTPD)

- 71,0941,020IGCC Specific Cost ($/kW)

-----448,000447,000Total IGCC Cost ($,000)

+53,0403,200Oxygen Plant Size (sTPD)

∆ (%)CryoASU

ITMOxygen

13© Air Products and Chemicals, Inc. 2001

ITM Oxygen is a three-phasedevelopment effort

Phase I - proof of concept– ceramic fabrication scale-up– process concept validation tests at lab-scale

14© Air Products and Chemicals, Inc. 2001

Ceramic Fabrication scaled-upin component size and volume

1

3

5

7

9

7/00

9/00

11/0

0

1/01

3/01

5/01

7/01

Rel

ativ

e M

embr

ane

Are

a

Transitioned to Full-SizeMembrane Components

in July 2000

15© Air Products and Chemicals, Inc. 2001

Oxygen flux from sub-scalemembranes meets target

Relat

ive O

xyge

n Fl

ux

Feb-99 Apr-00 Sep-00 Oct-00 Apr-01

1

2

3 Commercial RangePhase ITarget

ITM Material & CeramicProcessing Improvements

subscale membrane assemblies at T and PO2 typical for full process conditions

16© Air Products and Chemicals, Inc. 2001

ITM Oxygen is a three-phasedevelopment effort

Phase I - proof of concept– ceramic fabrication scale-up– process concept validation tests at lab-scale

Phase II - scale-up to 5 TPD– design, construction, testing of 5 TPD unit– engineering, cost, scale-up data for Phase III

Phase III - 25 TPD pre-commercial demo unit– fully integrated with gas turbine– tested at suitable field site

17© Air Products and Chemicals, Inc. 2001

Commercialization begins 2006

Phase II

Phase I

Phase IIICommercialization

Technical Feasibility0.1 TPD

Eng’g Prototypes1 & 5 TPD

Pre-commercial~25 TPD

CY 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

18© Air Products and Chemicals, Inc. 2001

DisclaimerA significant portion of this report was prepared by Air Productsand Chemicals, Inc. pursuant to a Cooperative Agreement partiallyfunded by the United States Department of Energy, and neither AirProducts and Chemicals, Inc. nor any of its contractors orsubcontractors nor the United States Department of Energy, norany person acting on behalf of either:1. Makes any warranty or representation, express or implied,with respect to the accuracy, completeness, or usefulness of theinformation contained in this report, or that the use of anyinformation, apparatus, method, or process disclosed in this reportmay not infringe privately owned rights; or2. Assumes any liabilities with respect to the use of, or fordamages resulting from the use of, any information, apparatus,method, or process disclosed in this report. Reference herein toany specific commercial products, process, or service by tradename, trademark, manufacturer, or otherwise, does not necessarilyconstitute or imply its endorsement, recommendation, or favoringby the United States Department of Energy. The views andopinions of authors expressed herein do not necessarily state orreflect those of the United States Department of Energy.

Thank youThis paper was written with support of the U.S. Department of Energyunder Contract No. DE-FC26-98FT40343. The Government reservesfor 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 copyrightedpaper.

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