Integration of Ion Transport Membrane Technology with Oxy-Combustion ...€¦ · • Single-stage high purity oxygen • All layers composed of the same ceramic material • Extremely

© 2010 Electric Power Research Institute, Inc. All rights reserved.

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

Merrill Quintrell – Electric Power Research Institute ([email protected]) E P Ted Foster – Air Products and Chemicals Inc. ([email protected]) 2nd International Oxyfuel Combustion Conference 12th–16th September 2011

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mailto:[email protected]�

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What Is Ion Transport Membrane (ITM) Oxygen?

ITM Oxygen

Unit

High Temperature /

High Pressure Air

99.5% O2

N2 / O2

Design options for ITM Oxygen process: – Power co-production – Minimum fuel consumption – Minimum CO2 emissions

Images courtesy Air Products. © Air Products. All rights reserved.

A proprietary ceramic membrane to separate oxygen from air

ITM Oxygen can be used for both IGCC and oxy-combustion power cycles

CO2 / H2O

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• Single-stage high purity oxygen • All layers composed of the same ceramic material • Extremely selective and very fast electrochemical

transport for oxygen • Very compact

0.45 tonne/day (0.5 ton/day)

module

Porous membrane support

Dense, slotted backbone

Dense membrane

Hot Compressed Air

High Purity Oxygen Product

Oxygen flowing from air through dense membrane

One Membrane in Module

Spacer


800-900oC (1500-1650oF) 14+ bara (200+ psia)

ITM Oxygen Membranes

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0.45 tonne/day (0.5 ton/day)

Stack Progression to Commercial-Size Wafers


ITM Oxygen – Wafers and Module Scale-up 0.9 tonne/day

(1 ton/day) Stack

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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-MWe 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 2009. 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

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ITM with Oxy-Combustion Study Scope of Work

• Provide an overview of first ideas on integrating ITM into oxy-combustion systems, and the strengths and weaknesses of each

• Performance modeling with cryogenic ASU for comparison

– No CO2 purification

– CO2 purification with 75% and 90% CO2 capture

• Performance modeling for three ITM cases (with CO2 purification)

– ITM O2: 1-Stage, Direct-Fired, O2 supply at 38oC (100oF)

– ITM O2: 2-Stage, Direct-Fired, O2 supply at 538oC (1000oF)

– ITM O2: 2-Stage, Oxy-Fired, O2 supply at 538oC (1000oF); ITM unit exhaust sent to the CO2 purification unit

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Potential Ways to Integrate ITM with Oxy

Case Integration Benefits Concerns Comment

1 ITM standalone using direct-fired natural gas (NG) combustor for heat

Power production, simplicity

CO2 produced is vented; cost of using NG; availability of NG

Simple concept but use of NG and CO2 production (although less than combined cycles) may limit use

2 ITM standalone using oxy-fueled fired heater

Power production; lower CO2 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 CO2 emissions; potentially higher efficiency; may have a lower operating cost due to less use of NG

Concerns include: high-temperature material requirements; impacts on boiler operation and startup; pressure drop

Need to address technical unknowns before this would be viable

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Feed Air Non-permeate, contains CO2

Oxygen Product, 38oC (100oF)

Expander Compressor

Heat Exchange

ITM Oxygen Unit

Non- permeate

Fuel

Oxygen Blower

Oxygen Cooling

ITM Options a. 1-stage, direct-fired cycle,

O2 supply at 38oC (100oF)

ITM Configurations in Study: Case a

Low Level Heat Recovery (optional)

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Feed Air Non-permeate, contains CO2


Expander Compressor

Heat Exchange

ITM Oxygen Unit (A)

Non- permeate

Fuel ITM Oxygen Unit (B) Oxygen

Cooling

Oxygen Blower


ITM Configurations in Study: Case b

ITM Options b. 2-stage, direct-fired cycle,

O2 supply at 538oC (1000oF)

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Feed Air

ITM Oxygen Unit (B) Oxygen

Cooling

Non-permeate

Oxygen Blower

Expander Compressor

Heat Exchange (optional)

ITM Oxygen Unit (A)

Non- permeate

Fuel

Heat Exchange

Oxy-fired Combustion

Flue Gases To CO2

Recovery

Oxygen

ITM Configurations in Study: Case c

ITM Options c. 2-stage, oxy-fired cycle, O2

supply at 538oC (1000oF)



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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% CO2 capture at 17% cost of electricity (COE) advantage over cryogenic oxygen cycles

– Oxy-fired ITM Oxygen cycles achieve 90% CO2 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

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• ITM Oxygen and Cryogenic ASU cycle cases:

1. Nominal 90% CO2 capture; 1%-point efficiency increase

2. Nominal 75% CO2 capture; 6%-point efficiency increase

NGCC/CCS

25%

30%

35%

40%

45%

50%

55%

0 500 (227) 1000 (455) 1500 (682) 2000 (909)

NGCC Conventional PC

Eff

icie

ncy

, HH

V

CO2 emissions, lb CO2/MWh (net) (kg CO2/MWh (net))

ITM

Cryogenic ASU

(2)

(1)

(1) (2) Oxy-Cryo ASU

Results Show Flexibility of ITM Process Options

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Conclusions

• ITM Oxygen is a promising technology for lower-cost oxygen production

• ITM Oxygen has potential for economic benefits for oxy-combustion 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 2013

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Acknowledgment and 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.

Acknowledgment

This technology development has been supported in part by the U.S. Department of Energy under Contract No. DE-FC26-98FT40343. 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

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Integration of Ion Transport Membrane Technology with Oxy-Combustion ...€¦ · • Single-stage high purity oxygen • All layers composed of the same ceramic material • Extremely