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This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the Department of Energy, National Energy Technology Laboratory (DOE NETL) on development of the second generation (Gen-2) Proteus™ membrane modules and a pre-combustion membrane process for carbon dioxide (CO₂) capture from an Integrated Gasification Combined Cycle (IGCC) plant for power generation (award number DE-FE0031632). The work was conducted from October 1, 2018 through March 30, 2022. The overall goal of this project was to bring a Gen-2 version of the H2-selective Proteus membrane to bench-scale module (component) testing with real syngas. MTR was assisted in this project by Susteon, a technology development company with extensive experience in gasification processes, and the University of North Dakota Energy & Environmental Research Center (EERC), who provided the host site for the slipstream field testing. This report details the work conducted to optimize the Gen-2 Proteus membrane and develop modules capable of operation at 200°C; demonstrate membrane module performance processing coal-derived syngas during a field test at EERC; and optimize integration of a dual-membrane process into an IGCC with carbon capture. Work for this project included membrane optimization and scale-up, module component screening and fabrication of high-temperature lab- and bench-scale modules, design and fabrication of a bench-scale field test membrane skid, operation of the field test skid processing coal-derived syngas at EERC, and a detailed techno-economic analysis (TEA) of the MTR dual-membrane process for IGCC power plant pre-combustion CO₂ capture. This project validated recent membrane technology advancements, mitigates risk in future scale-up activities, and moved the membrane pre-combustion capture technology from TRL-4 to TRL-5. Key results for each major task are discussed in the report.

The objective of the project is to conduct a Front-End Engineering Design (FEED) study to determine the technical and economic feasibility of installing a retrofit, post-combustion, carbon capture facility on a commercially operating, natural gas-fired, combined cycle (NGCC) power plant. The Electric Power Research Institute (EPRI), California Resources Corporation (CRC), and Fluor Corporation used Fluor's Econamine FG Plus^SM (EFG+) conducted the FEED study for capturing CO₂ produced by CRC's 550 MWe Elk Hills Power Plant (EHPP), located in the Elk Hills Oil Field near Tupman, Kern County, California. The EHPP was commissioned in 2003 and is powered by two General Electric 7FA gas turbines, with two heat recovery steam generators (HRSGs) providing steam to a General Electric D11 steam turbine. The target capture amount is 4,000 tonnes CO₂/day for use in either enhanced oil recovery or dedicated geological saline storage located on CRC property at or nearby EHPP. This CO₂ is captured from a combination of the CO₂ emitted from the flue gas from EHPP and the flue gas generated from a natural gas-fired auxiliary boiler that supplies steam to the EFG+ process.

This report provides an example of designing, developing, and running a power plant suitability model in the Energy Zones Mapping Tool (EZMT), a public, web-based mapping tool with a large spatial database focused on energy infrastructure, energy resources, and related siting factors. The example focuses on natural gas combined cycle (NGCC) power plants, which have several unique and interesting characteristics. NGCC plants typically provide peaking power to the electrical grid. Such plants can be started or stopped relatively quickly and are often used to supplement base load plants (such as nuclear or coal) during times of peak electrical consumption or to counterbalance lulls in variable power generation (such as wind or solar). Due to these and other factors, NGCC plants have been projected to increase in number under energy planning studies such as Hadley et al. The scope of the Hadley et. al. study is the Eastern Interconnection (EI), the electrical transmission grid serving much of the United States and Canada east of the Rocky Mountains. Results in the study are organized according to 22 Multi-region National—North American Electricity and Environment Model (NEEM) regions within the EI. NGCC plants usually have lower water requirements than other thermoelectric power plants they may replace; therefore, they are expected to have an interesting role in reducing the overall water requirements of energy generation.

The electrical transmission grid is a critical part of the U.S. national infrastructure, and its modernization is a U.S. Department of Energy (DOE) priority. We describe the Energy Zones Mapping Tool (EZMT), a unique, powerful, and public web-based system with multi-criteria decision analysis (MCDA) models for more than 20 power plant technologies and many other capabilities. Through a case study on natural gas combined cycle (NGCC) power plants in the Eastern Interconnection (EI), we provide an example of incorporating an EZMT MCDA model into a larger planning context, with projections of interconnection-level capacity expansion, thermoelectric power plant retirements, and water availability. Our results provide insights on candidate NGCC site distributions and the criteria influencing them. The case study provides both an efficient methodology for performing similar analyses and hundreds of candidate NGCC power plant sites that can be studied in more detail as potential project sites.

During phase-I, the project team led by Echogen Power Systems (EPS) had two primary objectives based on investigating the application of gas turbines with supercritical carbon dioxide (sCO₂) power cycles. The first objective was to improve the overall efficiency and performance of a hybrid gas turbine/sCO₂ power system through a joint optimization of the two subsystems (gas turbine and sCO₂ power cycle) using non-linear optimization techniques that simultaneously evaluate thermal performance of the combined cycle. The hybrid power system included several points of interaction, including (but not limited to) gas turbine exhaust, fuel heating, inlet chilling and turbine cooling. The second objective was to establish a baseline transient response model of the hybrid power system and a notional microgrid and begin steps to integrate the control systems of the three major elements (gas turbine, sCO₂ cycle and grid controller). The project team established a baseline performance for a combined cycle power plant using a production gas turbine and scaled sCO₂ power cycle only utilizing exhaust heat recovery. Echogen’s non-linear techno-economic optimization code was extended by adding gas turbine component models derived from a in-house developed gas turbine design code. With the two cycles coupled by the gas turbine exhaust, design parameters of both cycles were allowed to vary simultaneously to determine performance opportunity versus isolated designs. Returning to the baseline gas turbine/sCO₂ power cycle transient models: Echogen had in-house developed sCO₂ cycle transient model in GT-Suite system simulation software, and had partnered with Siemens Finspång for gas turbine transient model, and Siemens PTI group to provide micro-grid load profile as well as hybrid power cycle generated load (power and frequency) analysis. The transient model for the SGT-750 Siemens gas turbine was a “black-box” functional mock-up interface (FMI) model developed by Siemens Industrial Turbomachinery in Finspång, Sweden. The SGT-750 is a twin-shaft gas turbine that produces 40 MW electricity with an efficiency of about 40% at ISO conditions. At 100% gas turbine throttle (load), the SGT-750 has average exhaust conditions of 114.6 kg/s and 469.8°C. The transient model for sCO₂ power cycle was developed by Echogen in GT-SUITE 1D system simulation software platform. The basic CO₂ flow circuit has single-shaft turbomachinery with net 11.5 MW electrical power output at design conditions. The power turbine has a double-ended shaft with one end connected to synchronous generator through a fixed-ratio gearbox. The other end of power turbine is connected to the compressor through a continuously variable transmission. The major components of the sCO₂ power cycle modeled include air cooled condenser/cooler, CO₂ compressor, recuperator, two waste heat exchanger coils, power turbine, continuous variable transmission, gearbox and generator. Integration of SGT-750 transient model and sCO₂ power cycle transient model was done in Matlab Simulink. In the integrated model, the gas turbine and sCO₂ power cycle interacted at two points, first one being the gas turbine exhaust gas flow rate and temperature, which were inputs to sCO₂ power cycle model. The second point was the distribution of micro-grid load demand signal between the SGT-750 generator and sCO₂ cycle generator. For a given combined-cycle load demand, the gas turbine load demand was equal to the total demand minus the sCO₂ cycle power generated. In the present study the integrated model was simulated for two cases of grid load demand: (i) for a step change, both positive-step and negative-step, in grid load demand (ii) for a micro-grid load demand curve provided by Siemens PTI group. Finally, the time series plots representing load demand versus integrated system response were presented including the sCO₂ power cycle control system performance plots. The actual generated power and frequency of both the generators, gas turbine and sCO₂ power cycle, was supplied to Siemens PTI group for dynamic grid assessment, results of which are provided in appendices.

A comprehensive front-end engineering design (FEED) study has been undertaken by Bechtel National Inc. (Bechtel) for locating a post-combustion capture and compression (PCC) unit at Panda’s Sherman natural gas–combined cycle (NGCC) power plant in Sherman, Texas. This is described in the unredacted FEED Study report (Attachment 1) with all supporting documents, numbering over 150. The Study Report is publicly available. Sizing of the PCC plant is based on treating an amount of flue gas equivalent to that produced when generating 420 MW, which is approximately 68% of the total flue gas emitted by the NGCC power plant operating at guarantee condition with duct burners off. A reduced power plant capacity factor was used for sizing the PCC plant because the gas turbines at the site often operate at reduced load due to the high penetration of renewable power in the ERCOT region. The cost of carbon capture is primarily driven by capital cost (and therefore is highly sensitive to capacity factor). Sizing the capture unit so that when used it is nearly always operating at full capacity is critical to the economic viability of the proposed investment.

A comprehensive front-end engineering design (FEED) study has been undertaken for a post-combustion capture (PCC) unit located at Panda’s Sherman natural gas–combined cycle (NGCC) power plant in Sherman, Texas. This is described in a full and unredacted FEED study report with all supporting documents, numbering over 150, also publicly available.

In this project, TDA Research, Inc. (TDA) has further developed TDA’s chemical absorbent-based air separation process that can deliver low-cost oxygen to various advanced power generation systems, including oxygen-fired pulverized coal boilers and Integrated Gasification Combined Cycle (IGCC) power plants. TDA’s absorbent operates at high temperature and hence eliminates the thermodynamic inefficiencies inherent in the conventional cryogenic air separation units (ASUs). Unlike the sorbents used in commercial Pressure Swing Adsorption (PSA) systems, our sorbent selectively removes oxygen (not nitrogen); which allows the effective utilization of the large amounts of energy in the high pressure oxygen-depleted stream. As a result, the new air separation system is very efficient and delivers a low cost oxygen product. TDA, in collaboration with University of California, Irvine has increased the technical maturity and commercial viability of the new technology by: 1) demonstrating continuous oxygen generation at 0.1 kg/h with 98+% purity in a 4-bed prototype test system, and 2) carrying out a high fidelity process design and economic analysis. With the successful completion of the R&D effort, the technology is now ready for a larger pilot-scale demonstration and the technology readiness has been raised from TRL 4 to TRL 6. We demonstrated the prototype unit for more than 1,800 hours producing high purity oxygen. TDA’s ASU unit provides significant improvement in overall plant performance, increasing the net plant efficiency of an integrated gasification combined cycle (IGCC) power plant from 32%(in the case where cryogenic air separation is used to produce oxygen) to 34.05% for the cold gas cleanup case for GE gasifier. TDA’s chemically driven oxygen separation process also improves the efficiency of a system that incorporates warm gas cleanup, but the improvement is smaller at 35.33% vs 34.46%. The 1st year Cost of Electricity (COE) and the Cost of CO₂ Capture are also lower for the TDA ASU when compared to the cryogenic ASU. For an IGCC powerplant integrated with a cold gas cleanup system that uses GE gasifier, the use of TDA ASU instead of a cryogenic unit reduces the COE per MWh from $$\$$ $142 to $$\$$ $127.1 while the cost of CO₂ capture including TS&M goes from $$\$$ $47 to $$\$$ $32 per tonne. However for an IGCC power plant integrated with a warm gas cleanup system the reduction is smaller, the COE per MWh is $$\$$ $134 vs $$\$$ $121.9 while the cost of CO₂ capture including TS&M is $$\$$ $41 vs $$\$$ $27 per tonne.

This final report to DOE/NETL presents all the work and tests performed during ION Engineering’s (ION) carbon dioxide (CO₂) capture pilot test campaign: “ION Advanced Solvent CO₂ Capture Project”. This project is comprised of three budget periods (BP): BP1 – Design of a 0.6 MWe system, BP2 – 0.5 MWe National Carbon Capture Center (NCCC) Testing Campaign, and BP3 – 12 MWe Technology Center at Mongstad (TCM) Testing Campaign. The program began in October 2013 and continued until December 2017. The campaign at NCCC, which took place from June to August of 2015, resulted in 1,116 operational hours where ~350 tonnes of CO₂ were captured from the 0.5 MWe coal-fired flue gas slipstream. The follow-up campaign at TCM took place from Oct 2016 to April 2017, where 2,775 hours of operation resulted in the capture of 14,820 tonnes of CO₂, which is a cumulative of capturing CO₂ from the natural gas-fired Combined Heat and Power (CHP) plant, and a residue fluid catalytic cracker gas (RFCC) from Statoil at Mongstad. ION has conducted a thoughtful, comprehensive, and successful program in close collaboration with all its partners. CO₂ was successfully removed and captured for extended periods of time using three gas sources (NCCC Coal-fired Power plant, TCM CHP flue gas with and without CO₂ recycle, and TCM RFCC flue gas with air dilution) at various slipstream flows ranging from 0.5 MWe to 12 MWe. The data gathered on its solvent continues to strengthen the development of ION’s advanced solvent and positive track record in executing on-site test campaigns in highly industrialized settings. These existing pilot plants do not include the necessary process modifications that ION requires to obtain the lowest possible regeneration energy; processes such as a cold-rich bypass and intercooling, would allow for lowering the demonstrated specific reboiler duty. The resulting data was also used to validate the process model, and, in the absence of testing on a custom test rig specifically designed for ION’s advanced solvent, the results of the process model have shown specific reboiler duties under 2.5 MJ/kg CO₂ (1075 BTU/lb CO₂). When these regeneration energies are factored into the Techno-Economic Analysis (TEA), where ION’s technology is compared to the DOE/NETL BBS Case 12, which integrates a highly optimized and commercially available CO₂ capture technology, ION’s technology shows: 38% incremental reduction in capital cost of CO₂ capture; 28% incremental reduction in annual operating and maintenance costs of CO₂ capture; and $35-44 per tonne of CO₂ capture, which is a 20% to 40% reduction in cost of CO₂ capture. Throughout pilot testing, ION has confirmed its understanding of process improvements and analytics that will enable successful operation of its advanced solvent at significantly lower L/G circulation rates, packing heights and regeneration energies than MEA. ION has identified routes to further develop its technology and is looking forward to testing a fully optimized solvent and capture system in the near future.