Integration of Ion Transport Membrane Technology with Oxy-Combustion Power Generation Systems

Transcription

1 Integration of Ion Transport Membrane Technology with Oxy-Combustion Power Generation Systems Merrill Quintrell Electric Power Research Institute E P Ted Foster Air Products and Chemicals Inc. (fosterp@airproducts.com) 2nd International Oxyfuel Combustion Conference 12th 16th September Electric Power Research Institute, Inc. All rights reserved.

2 What Is Ion Transport Membrane (ITM) Oxygen? A proprietary ceramic membrane to separate oxygen from air Design options for ITM Oxygen process: Power co-production Minimum fuel consumption Minimum CO 2 emissions Images courtesy Air Products. Air Products. All rights reserved. High Temperature / High Pressure Air ITM Oxygen Unit 99.5% O 2 N 2 / O 2 CO 2 / H 2 O ITM Oxygen can be used for both IGCC and oxy-combustion power cycles 2

3 ITM Oxygen Membranes Single-stage high purity oxygen All layers composed of the same ceramic material Extremely selective and very fast electrochemical transport for oxygen Very compact Dense membrane Oxygen flowing from air through dense membrane One Membrane in Module Porous membrane support Hot Compressed Air o C ( o F) 14+ bara (200+ psia) 3 High Purity Oxygen Product Dense, slotted backbone Spacer 0.45 tonne/day (0.5 ton/day) module Images courtesy Air Products. Air Products. All rights reserved.

4 ITM Oxygen Wafers and Module Scale-up 0.9 tonne/day (1 ton/day) Stack Progression to Commercial-Size Wafers 0.45 tonne/day (0.5 ton/day) Stack Images courtesy Air Products. Air Products. All rights reserved. 4

5 ITM Oxygen Development Background Air Products (AP) has been developing ITM since 1988 and the Department of Energy (DOE) has been a principal funder of the technology since 1998 AP/DOE development program is currently in Phase 3, with goal to design, build, and test an ITM Intermediate-Scale Test Unit (ISTU) 90 tonnes/day (100 tons/day) integrated with 5-MW e turbomachinery system U.S. DOE NETL, AP, EPRI, and others are involved DOE awarded additional US$65 million for expanding Phase 3 and US$71.7 million for Phase 5 to install a ceramic fabrication plant and to prepare for a 1800 tonnes/day (2000 tons/day) pre-commercial scale facility EPRI initiated a power industry-led collaborative to support the program in Project funders received: Background on ITM: its ceramics, development, and production Detailed performance modeling and economic assessment of ITM applied to both IGCC and oxy-combustion Integration schemes for ITM into IGCC and oxy-combustion Quarterly web-casts and annual site visits (ceramics facility, AP HQ, pilot site) Current EPRI project ends September 2011 with a plan to extend it 5

6 ITM with Oxy-Combustion Study Scope of Work Provide an overview of first ideas on integrating ITM into oxycombustion systems, and the strengths and weaknesses of each Performance modeling with cryogenic ASU for comparison No CO 2 purification CO 2 purification with 75% and 90% CO 2 capture Performance modeling for three ITM cases (with CO 2 purification) ITM O 2 : 1-Stage, Direct-Fired, O 2 supply at 38 o C (100 o F) ITM O 2 : 2-Stage, Direct-Fired, O 2 supply at 538 o C (1000 o F) ITM O 2 : 2-Stage, Oxy-Fired, O 2 supply at 538 o C (1000 o F); ITM unit exhaust sent to the CO 2 purification unit 6

7 Potential Ways to Integrate ITM with Oxy Case Integration Benefits Concerns Comment 1 ITM standalone using directfired natural gas (NG) combustor for heat Power production, simplicity CO 2 produced is vented; cost of using NG; availability of NG Simple concept but use of NG and CO 2 production (although less than combined cycles) may limit use 2 ITM standalone using oxyfueled fired heater Power production; lower CO 2 emissions, coal may be used rather than NG Complexity and capital cost compared to Case 1; cost / availability of NG if used; developing fired heater May be the best of the options unless capital cost is a principal concern 3 ITM integrated into boiler for heat Lower CO 2 emissions; potentially higher efficiency; may have a lower operating cost due to less use of NG Concerns include: hightemperature material requirements; impacts on boiler operation and startup; pressure drop Need to address technical unknowns before this would be viable 7

8 ITM Configurations in Study: Case a Feed Air Non-permeate, contains CO 2 Low Level Heat Recovery (optional) Compressor Expander ITM Options a. 1-stage, direct-fired cycle, O 2 supply at 38 o C (100 o F) Heat Exchange Fuel Nonpermeate ITM Oxygen Unit Oxygen Blower Oxygen Cooling 8 Oxygen Product, 38 o C (100 o F)

9 ITM Configurations in Study: Case b Feed Air Non-permeate, contains CO 2 Low Level Heat Recovery (optional) Compressor Expander ITM Options b. 2-stage, direct-fired cycle, O 2 supply at 538 o C (1000 o F) Heat Exchange Fuel ITM Oxygen Unit (B) Oxygen Cooling Oxygen Blower Nonpermeate ITM Oxygen Unit (A) Oxygen Product, 538 o C (1000 o F) 9

10 ITM Configurations in Study: Case c Feed Air Non-permeate Low Level Heat Recovery (optional) Compressor Flue Gases To CO 2 Recovery Expander Heat Exchange (optional) ITM Options c. 2-stage, oxy-fired cycle, O 2 supply at 538 o C (1000 o F) ITM Oxygen Unit (B) Oxygen Cooling Oxygen Blower Heat Exchange Nonpermeate ITM Oxygen Unit (A) Fuel Oxy-fired Combustion Oxygen Oxygen Product, 538 o C (1000 o F) 10

11 Summary of Oxy-Combustion Modeling Results ITM Oxygen can contribute significantly to the overall power production of an oxy-combustion facility ITM Oxygen affords increased power cycle efficiency over cryogenic oxygen production At base-case fuel costs: Direct-fired ITM Oxygen cycles achieve 75% CO 2 capture at 17% cost of electricity (COE) advantage over cryogenic oxygen cycles Oxy-fired ITM Oxygen cycles achieve 90% CO 2 capture at equivalent COE to cryogenic oxygen-based cycles, but with 14% reduction in specific plant capital cost Lower natural gas costs increase the advantage of ITM Oxygen over cryogenic systems Preliminary results with potential improvements in integration to come 11

12 Results Show Flexibility of ITM Process Options ITM Oxygen and Cryogenic ASU cycle cases: 1. Nominal 90% CO 2 capture; 1%-point efficiency increase 2. Nominal 75% CO 2 capture; 6%-point efficiency increase Efficiency, HHV 55% 50% 45% 40% 35% 30% NGCC Conventional PC NGCC/CCS (2) (1) 25% (1) (2) Oxy-Cryo ASU ITM Cryogenic ASU (227) 1000 (455) 1500 (682) 2000 (909) CO 2 emissions, lb CO 2 /MWh (net) (kg CO 2 /MWh (net)) 12

13 Conclusions ITM Oxygen is a promising technology for lower-cost oxygen production ITM Oxygen has potential for economic benefits for oxycombustion power generation ITM Oxygen will be significantly scaled up in the next few years in the 90 tonnes/day (100 tons/day) oxygen ISTU pilot plant Following the ISTU, the next step is a 1800 tonnes/day (2000 tons/day) facility in the late 2015 timeframe A ceramic fabrication facility to produce modules for a commercial-scale ITM Oxygen facility will be operating in

14 Acknowledgment and Disclaimer Acknowledgment This technology development has been supported in part by the U.S. Department of Energy under Contract No. DE-FC26-98FT 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 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; or 2. 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. 14

15 Together Shaping the Future of Electricity 15