TDA Research Inc. Wheat Ridge, CO 80033 www.tda.com

Cost Effective Air Separation System (Contract No. DE-FE-0024060)

Gökhan AlptekinAmbal JayaramanRobert Copeland

DOE Gasification Systems and Coal & Coal-Biomass to

Liquids Workshop

Morgan town, WV

August 10, 2015

TDAR e s e a r c h

Project Objective

• The project objective is to demonstrate techno-economic viability of a new air separation technology that can be integrated into the coal gasification and oxy-combustion process

• A high temperature chemical absorbent that is selective for O2removal is the key for the process• Early proof-of-concept demonstrations in an SBIR Phase II project

high oxygen uptake and stable performance• Project Tasks

• Sorbent optimization and scale-up• Testing in a fully-equipped sub-scale unit to fully demonstrate the

concept at the bench-scale• Bench-top demonstration of life (min 10,000 cycles)• A high fidelity process design and cost analysis supported by Aspen

PlusTM simulations• IGCC process and oxy-combustion

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Project Partners

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• A second contract is being worked out to carry-out prototype evaluation (DE-FE-0026142)

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Introduction Oxygen-blown gasifiers provides

smaller size and higher efficiency and substantially reduce NOx and improve gas purity with the removal of N2

ASU is one of the largest cost items in an IGCC plant (consumes 5% of plant power and constitutes ~15% of plant cost)

Low cost oxygen is also critical for the oxy-combustion applications

The cryogenic air separation is the choice of technology at large-scale 600 MW gasifier requires ~170 ton

O2/day Cryo-separation is highly energy

intensive due to the thermal inefficiencies inherent in the low operating temperatures

Air-fired Oxy-fired210 MW oxy-fired PC combustion power plant (Nskala et al., 2008)

(Kobayashi, 2002)

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TDA’s Approach

TDA’s process uses a unique sorbent to support an oxidation-reduction (redox) process

Unlike conventional chemical looping combustion sorbents that also work via a similar redox process, oxygen can be released by changing process conditions No use of reducing gases (e.g., CH4, H2, CO, syngas) that will

consume oxygen MOx = MOy + x/2y O2(g)

The metal oxide phase auto-reduces by changing T, P, oxygen partial pressure The auto-reduction releases oxygen, which can be recovered as a

pure product

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Separation Process Sorbent removes some (~30%)

but not all the O2 from high pressure air drawn into the gas turbine Vitiated high pressure air put

back in the GT after boosting the pressure

Regeneration is carried out using warm sweep gas (superheated steam) ideallyunder isobaric/isothermal conditions Partial pressure difference to

drive the O2 from the sorbent Other options

Pressure swing assisted regeneration

Temperature swing assisted Pressure swing

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Integrated with IGCC Power Plant

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Process Scheme #1

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Integration to the IGCC/CTL Plant

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Particul. Removal

Acid Gas Removal

Cont. RemovalGasifier

Coal

Oxygen

Air

Exhaust

Steam Turbine

Gas Turbine

HRSG

RegenerationAbsorption

Combustor

Steam

Clean syngas to combined cycle

Clean syngas to chemical

plant (optional)

CombustorWater

Condenser

Water

SteamSyngas

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645-77 - Sorbent #1

25.0

25.1

25.2

25.3

25.4

25.5

0 200 400 600 800 1000

Time, min

Wei

ght,

mg

670

680

690

700

710

720

Tem

pera

ture

(o C)

O2/N2 cycling41 cycles

Cycle duration = 17 minWeight change = 1.11%

T = 700C

Mn3O4 cycling at 800oC

14.8

14.9

15

15.1

15.2

15.3

15.4

15.5

0 200 400 600 800 1000 1200 1400Time, min

Wei

ght,

mg

700

720

740

760

780

800

820N2/O2 cycling 210 cycles Cycle time = 10 min

wt. Change = 3.63%

Temperature, oC

Early Results in TGA

Sorbent can be regenerated by concentration swing Switching from pure O2 to

pure N2

Higher capacity at 800oC 3.63% wt. O2 loading at

800oC (10 min full cycle time)

T=800oC

T=700oC

• Similar trends at 700oC• Lower capacity if the same

cycle time is maintained due to slower kinetics during regeneration

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Sorbent Optimization

Oxygen release was documented over a wide range of temperatures

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Flow Experiments in Small & Large Reactors

Oxygen release was documented over a wide range of reactor configurations

0

5

10

15

20

25

0 100 200 300 400Time (min)

Oxy

gen

conc

entr

atio

n (%

)

0

200

400

600

800

1000

Pres

sure

(psi

g) /

Tem

pera

ture

(o C)

OxygenpressureTemperature

absorption step desorption step

2” InconelReactor

Tube Furnace

Pressure control valve

On-line O2Analyzer

Control Box

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Long-term Durability

Sorbent maintained performance for 200 cycles12

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System Design

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Absorption Process

Heat Exchanger

O2Regeneration

Heat Recovery Steam 

Generator

O2

Water

Water

LP Steam and Natural Gas

O2 and Steam

LP Steam

Regeneration Process

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IGCC without CO2 Capture

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TDA Steam Plant ChangesScaled up Steam Plant 292,692Steam extration ‐43,351LP steam Generated 11,194Methane expander 540Net Steam Power 261,075

Auxiliary PowerGT Air Boost 584Added Air Compressor 60,617O2 Compressor  10,260Internal O2 Compressor 10,981Net Axilary Load changes 82,441

Power SummaryGas Turbine Power, kW 515,395Sweet Gas Expander, kW 7,500Stem Turbine, kW 261,075Total Power, kW 783,970Auxiliary Load, kW 109,771Net Power, kWe 674,199Net Plant Efficiency %, HHV 40.43%

GE Gasifier

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Preliminary Process Analysis

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IGCC without CO2 Capture (GE Gasifier – DOE Case 1) New sorbent-based ASU can increase the plant efficiency to

40.4%, in comparison to 39% with the same plant equipped with cryogenic separation

Cost of electricity (COE) on a $2011 basis is expected to be $93.2 per MWhr (versus $101.2 per MWhr with cryogenic ASU)

IGCC with CO2 Capture (GE Gasifier – DOE Case 2) New sorbent-based ASU could reduce the cost of CO2 captured

on a $ 2011 basis, for both the conventional Selexol-based and TDA’s warm gas CO2 capture technology to $38.8/tonne and $29.3/tonne respectively

Assumption = Cost of the new ASU is the same as cryogenic plant

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Vision for Commercialization

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• Slipstream to pilot-scale demonstrations to increase technical maturity from TRL = 4 to TRL = 6

• Develop a complete technology package for licensing• Intellectual Property• Process Design Package• Sorbent Manufacturing

• Privately Owned / Began operations in 1987• Two facilities in Wheat Ridge and Golden, CO

• 50,000 ft2 of office and lab space• 82 full-time technical staff

• More than half with advanced degrees (28 PhDs)

C 60 (Ih)

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Contact

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Gokhan Alptekin, PhDVice President, Technology

TDA Research, Inc.12345 W. 52nd Avenue

Wheat Ridge, CO 80033Tel: 303 940 2349Fax: 303 422 7763Cell:720 352 7919

Email: galptekin@tda.com