Membrane Process to Capture CO{sub 2} from Coal-Fired Power Plant Flue Gas
This final report describes work conducted for the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL) on development of an efficient membrane process to capture carbon dioxide (CO{sub 2}) from power plant flue gas (award number DE-NT0005312). The primary goal of this research program was to demonstrate, in a field test, the ability of a membrane process to capture up to 90% of CO{sub 2} in coal-fired flue gas, and to evaluate the potential of a full-scale version of the process to perform this separation with less than a 35% increase in the levelized cost of electricity (LCOE). Membrane Technology and Research (MTR) conducted this project in collaboration with Arizona Public Services (APS), who hosted a membrane field test at their Cholla coal-fired power plant, and the Electric Power Research Institute (EPRI) and WorleyParsons (WP), who performed a comparative cost analysis of the proposed membrane CO{sub 2} capture process. The work conducted for this project included membrane and module development, slipstream testing of commercial-sized modules with natural gas and coal-fired flue gas, process design optimization, and a detailed systems and cost analysis of a membrane retrofit to a commercial power plant. The Polaris? membrane developed over a number of years by MTR represents a step-change improvement in CO{sub 2} permeance compared to previous commercial CO{sub 2}-selective membranes. During this project, membrane optimization work resulted in a further doubling of the CO{sub 2} permeance of Polaris membrane while maintaining the CO{sub 2}/N{sub 2} selectivity. This is an important accomplishment because increased CO{sub 2} permeance directly impacts the membrane skid cost and footprint: a doubling of CO{sub 2} permeance halves the skid cost and footprint. In addition to providing high CO{sub 2} permeance, flue gas CO{sub 2} capture membranes must be stable in the presence of contaminants including SO{sub 2}. Laboratory tests showed no degradation in Polaris membrane performance during two months of continuous operation in a simulated flue gas environment containing up to 1,000 ppm SO{sub 2}. A successful slipstream field test at the APS Cholla power plant was conducted with commercialsize Polaris modules during this project. This field test is the first demonstration of stable performance by commercial-sized membrane modules treating actual coal-fired power plant flue gas. Process design studies show that selective recycle of CO{sub 2} using a countercurrent membrane module with air as a sweep stream can double the concentration of CO{sub 2} in coal flue gas with little energy input. This pre-concentration of CO{sub 2} by the sweep membrane reduces the minimum energy of CO{sub 2} separation in the capture unit by up to 40% for coal flue gas. Variations of this design may be even more promising for CO{sub 2} capture from NGCC flue gas, in which the CO{sub 2} concentration can be increased from 4% to 20% by selective sweep recycle. EPRI and WP conducted a systems and cost analysis of a base case MTR membrane CO{sub 2} capture system retrofitted to the AEP Conesville Unit 5 boiler. Some of the key findings from this study and a sensitivity analysis performed by MTR include: The MTR membrane process can capture 90% of the CO{sub 2} in coal flue gas and produce high-purity CO{sub 2} (>99%) ready for sequestration. CO{sub 2} recycle to the boiler appears feasible with minimal impact on boiler performance; however, further study by a boiler OEM is recommended. For a membrane process built today using a combination of slight feed compression, permeate vacuum, and current compression equipment costs, the membrane capture process can be competitive with the base case MEA process at 90% CO{sub 2} capture from a coal-fired power plant. The incremental LCOE for the base case membrane process is about equal to that of a base case MEA process, within the uncertainty in the analysis. With advanced membranes (5,000 gpu for CO{sub 2} and 50 for CO{sub 2}/N{sub 2}), operating with no feed compression and low-cost CO{sub 2} compression equipment, an incremental LCOE of $33/MWh at 90% capture can be achieved (40% lower than the advanced MEA case). Even with lower cost compression, it appears unlikely that a membrane process using high feed compression (>5 bar) can be competitive with amine absorption, due to the capital cost and energy consumption of this equipment. Similarly, low vacuum pressure (<0.2 bar) cannot be used due to poor efficiency and high cost of this equipment. High membrane permeance is important to reduce the capital cost and footprint of the membrane unit. CO{sub 2}/N{sub 2} selectivity is less important because it is too costly to generate a pressure ratio where high selectivity can be useful. A potential cost ?sweet spot? exists for use of membrane-based technology, if 50-70% CO{sub 2} capture is acceptable. There is a minimum in the cost of CO{sub 2} avoided/ton that membranes can deliver at 60% CO{sub 2} capture, which is 20% lower than the cost at 90% capture. Membranes operating with no feed compression are best suited for lower capture rates. Currently, it appears that the biggest hurdle to use of membranes for post-combustion CO{sub 2} capture is compression equipment cost. An alternative approach is to use sweep membranes in parallel with another CO{sub 2} capture technology that does not require feed compression or vacuum equipment. Hybrid designs that utilize sweep membranes for selective CO{sub 2} recycle show potential to significantly reduce the minimum energy of CO{sub 2} separation.
- Research Organization:
- Membrane Technology And Research, Incorporated
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- NT0005312
- OSTI ID:
- 1089151
- Country of Publication:
- United States
- Language:
- English
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