Design and operation of pilot plant for CO2 capture from IGCC flue gases by combined cryogenic and hydrate method

This project is a trial conducted under contract with CO₂CRC, Australia of a new CO₂ capture technology that can be applied to integrated gasification combined cycle power plants and other industrial gasification facilities. The technology is based on combination of two low temperature processes, namely cryogenic condensation and the formation of hydrates, to remove CO₂ from the gas stream. The first stage of this technology is condensation at −55 °C where CO₂ concentration is expected to be reduced by up to 75 mol%. Remaining CO₂ is captured in the form of solid hydrate at about 1 °C reducing CO₂ concentration down to 7 mol% using hydrate promoters. This integrated cryogenic condensation and CO₂ hydrate capture technology hold promise for greater reduction of CO₂ emissions at lower cost and energy demand. Overall, the process produced gas with a hydrogen content better than 90 mol%. The concentrated CO₂ stream was produced with 95-97 mol% purity in liquid form at high pressure and is available for re-use or sequestration. The enhancement of carbon dioxide hydrate formation and separation in the presence of new hydrate promoter is also discussed. A laboratory scale flow system for the continuous production of condensed CO₂ and carbon dioxide hydrates is also described and operational details are identified.     

CO2 sequestration from coal fired power plants

The paper takes into consideration a new approach for CO₂ capture and transport, based on the formation of solid CO₂ hydrates.Carbon dioxide sequestration from power plants can take advantage of the properties of gas hydrates. The formation and decomposition of hydrates from various N₂-CO₂ mixtures has been studied experimentally in a 2 l reactor, to determine the CO₂ separation in terms of hydrate composition and residual CO₂ content in the reacted gas.Carbon dioxide acts as a co-former for the production of hydrates containing nitrogen, besides CO₂. The mixed hydrates that are obtained are less stable than simple CO₂ hydrates. When CO₂ content in the flue gas is higher than 30% by volume, the hydrates formed at 5 MPa are sufficiently concentrated (about 70% CO₂) and carbon dioxide reduction in the reacted gas is acceptable.The application of a process based on hydrate formation could be especially interesting (for CO₂ capture and transport) when connected to an oxy-coal combustion process; in this case the CO₂ content in the flue gas is very high and the hydrate formation is greatly facilitated.     

Gas hydrate formation from hydrogen/carbon dioxide and nitrogen/carbon dioxide gas mixtures

Gas hydrates from CO₂/N₂ and CO₂/H₂ gas mixtures were formed in a semi-batch stirred vessel at constant pressure and temperature of 273.7 K. These mixtures are of interest to CO₂ separation and recovery from flue gas and fuel gas, respectively. During hydrate formation the gas uptake was determined and the composition changes in the gas phase were obtained by gas chromatography. The rate of hydrate growth from CO₂/H₂ mixtures was found to be the fastest. In both mixtures CO₂ was found to be preferentially incorporated into the hydrate phase. The observed fractionation effect is desirable and provides the basis for CO₂ capture from flue gas or fuel gas mixtures. The separation from fuel gas is also a source of H₂. The impact of tetrahydrofuran (THF) on hydrate formation from the CO₂/N₂ mixture was also observed. THF is known to substantially reduce the equilibrium formation conditions enabling hydrate formation at much lower pressures. THF was found to reduce the induction time and the rate of hydrate growth.     

Thermodynamic stability, spectroscopic identification and cage occupation of binary CO2 clathrate hydrates

The hydrate phase behavior of CO₂/3-methyl-1-butanol (3M1B)/water, CO₂/tetrahydrofuran (THF)/water and CO₂/1,4-dioxane (DXN)/water was investigated using both a high-pressure equilibrium viewing cell and a kinetic pressure-temperature measurement system with a constant volume. The dissociation pressures of CO₂/3M1B/water were identical to those of pure CO₂ hydrate, indicating that CO₂ is not acting as a help gas for structure H hydrate formation with 3M1B, thus the formed hydrate is pure CO₂ structure I hydrate. The CO₂ molecules could be encaged in small cages of the structure II hydrate framework formed with both of THF and DXN. For a stoichiometric ratio of 5.56 mol% THF, we found a large shift of dissociation boundary to lower pressures and higher temperatures from the dissociation conditions of pure CO₂ hydrate. From the measurements using the kinetic pressure-temperature system, it was found that the solid binary hydrate samples formed from off-stoichiometric THF and DXN aqueous solutions are composed of pure CO₂ hydrate with a hydrate number n=7.0 and THF/CO₂ and DXN/CO₂ binary hydrates with a molar ratio of xCO₂·THF·17H₂O and xCO₂·DXN·17H₂O, respectively. The X-ray diffraction was used to identify the binary hydrate structure and Raman spectroscopy was measured to support the phase equilibrium results and to investigate the occupation of CO₂ molecules in the cages of the hydrate framework.     

Safe storage of Co2 together with improved oil recovery by Co2-enriched water injection

The 2007 IEA's World Energy Outlook report predicts that the world's energy needs will grow by 55% between 2005 and 2030, with fossil fuels accounting for 84% of this massive projected increase in energy demand. An undesired side effect of burning fossil fuels is carbon dioxide (CO₂) emission which is now widely believed to be responsible for the problem of global warming. Various strategies are being considered for addressing the increase in demand for energy and at the same time developing technologies to make energy greener by reducing CO₂ emissions.One of these strategies is to ‘capture’ produced CO₂ instead of releasing it into the atmosphere. Capturing CO₂ and its injection in oil reservoirs can lead to improved oil recovery as well as CO₂ retention and storage in these reservoirs. The technology is referred to as CCS (carbon capture and storage). Large point sources of CO₂ (e.g., coal-fired power plants) are particularly good candidates for capturing large volumes of CO₂. However, CO₂ capture from power plants is currently very expensive. In addition to high costs of CO₂ capture, the very low pressure of the flue gas (1 atm) and its low CO₂ content (typically 10-15%) contribute to the high cost of CO₂ capture from power plants and the subsequent compression. This makes conventional CO₂ flooding (which requires very large volumes of CO₂) uneconomical in many oil reservoirs around the world which would otherwise be suitable candidates for CO₂ injection. Alternative strategies are therefore needed to utilize smaller sources of CO₂ that are usually available around oil and gas fields and can be captured at lower costs (due to their higher pressure and higher CO₂ concentration).We investigate the potential of carbonated (CO₂-enriched) water injection (CWI) as an injection strategy for improving recovery from oil reservoirs with the added benefit of safe storage of CO₂. The performance of CWI was investigated by conducting high-pressure flow visualization as well as coreflood experiments at reservoir conditions. The results show that CWI significantly improves oil recovery from water flooded porous media. A relatively large fraction of the injected CO₂ was retained (stored) in the porous medium in the form of dissolved CO₂ in water and oil. The results clearly demonstrate the huge potential of CWI as a productive way of utilizing CO₂ for improving oil recovery and safe storage of potentially large cumulative quantities of CO₂.     

Dynamic measurements of hydrate based gas separation in cooled silica gel

Hydrate based gas separation is a promising method for carbon dioxide capture. The purpose of this study is to analyze hydrates formation and dissociation characters when gas mixture flows through cooled silica gel. The additives mixture (THF/SDS) was used to saturate the silica gel partly, and gas mixture (CO₂/H₂) was injected into it to form hydrates. Magnetic resonance imaging (MRI) images were obtained using fast spin echo multi-slice pulse sequence. Hydrates saturations were calculated quantitatively using MRI data. The experimental results showed that the optimal initial solution saturation was 34.2% in this investigation. The gas component was analyzed to assess the separation efficiency. For hydrates dissociation processes at 1 atmospheric pressure, CO₂ concentrations increased obviously. Half of the six cycles showed that more than 85.00 mol% CO₂ contained in the capture gas, and the lowest CO₂ concentration was 64.83 mol%. Hydrate blockages appeared frequently, which restricted the contact of gas and solution and caused the incomplete transformations of residual solution to hydrates. It was a key restricted factor for hydrate based CO₂ capture.     

Synthesis and reaction mechanism of Ti3SiC2 ternary compound by carbothermal reduction of TiO2 and SiO2 powder mixtures

The present study aims to investigate synthesis of Ti₃SiC₂ from TiO₂ and SiO₂ powder mixtures by carbothermal reduction method. Equilibrium TiO₂–SiO₂–C ternary phase diagram was used to predict the conditions for the formation of Ti₃SiC₂ at 1800 K under Ar atmosphere. A reactant mixture with a TiO₂:SiO₂ molar ratio of 1.5 and a C content of 68.75 mol% (26.86 wt%) was initially selected among the thermodynamically favorable reactant compositions for the experimental studies. Two different C sources, graphite flakes and pyrolytic C coating, were used to synthesize Ti₃SiC₂ at 1800 K under Ar atmosphere. When graphite flakes were used, the products contained a trace amount of Ti₃SiC₂ phase along with major TiC and minor SiC phases. Whereas, pyrolytic C coating on the oxide particles resulted in the products with much higher Ti₃SiC₂ contents owing to the close contact between the reactants. Optimal C concentration for the C coated oxide mixtures with a TiO₂:SiO₂ molar ratio of 1.5 was determined to be 30.05 wt% under the experimental conditions studied. Ti₃SiC₂ content of the products obtained from this reactant was observed to increase with reaction time to 31 wt% at 75 min beyond which it gradually decreased. XRD studies indicated that the product with the highest ternary carbide content also contained TiC and a trace amount of SiC. SEM-EDS analyses showed that this sample essentially consisted of spherical fine TiC particles and Ti₃SiC₂ nanolaminates. Equilibrium thermodynamic analysis of the TiO₂–SiO₂–C system suggested that the reaction of solid Ti₂O₃ with SiO and CO gases may play a dominant role in the formation of Ti₃SiC₂.     

CO2 capture enhancement by forming tetra-n-butyl ammonium bromide semiclathrate in graphite nanofluids

In this work, CO₂ capture was experimentally investigated by forming tetra-n-butyl ammonium bromide (TBAB) semiclathrate in a new system of TBAB + graphite nanofluids. The experiments were carried out at 3.5 MPa and 277.15 K. Compared to the TBAB solution and the TBAB + sodium dodecyl sulphate (SDS) solution, it was found that the system of TBAB + graphite nanofluids was preferable for CO₂ capture, and 0.2 wt.% graphite nanoparticles (GNP) was an optimal concentration for the enhancement of hydrate growth in TBAB + graphite nanofluids. At this GNP concentration, CO₂ consumption gained at 0.29 mol% TBAB is greater than that acquired at 0.62 and 2.57 mol% TBAB. CO₂ consumption obtained in TBAB + graphite nanofluids is larger than other systems containing GNP. Moreover, the morphologies of TBAB + CO₂ semiclathrate formed in TBAB solution, TBAB + SDS solution, and TBAB + graphite nanofluids were presented, and the mechanism of CO₂ capture using TBAB semiclathrate formation in graphite nanofluids was presented. Therefore, it is an efficient way to capture CO₂ by forming TBAB semiclathrate in graphite nanofluids.     

Study on the influence of SDS and THF on hydrate-based gas separation performance

Hydrate additives can be used to mitigate hydrate formation conditions, promote hydrate growth rate and improve separation efficiency. CO₂ + N₂ and CO₂ + CH₄ systems with presence of sodium dodecyl sulfate (SDS) or tetrahydrofuran (THF) are studied to analyze the effect of hydrate additives on gas separation performance. The experiment results show that CO₂ can be selectively enriched in the hydrate phase. SDS can speed up the hydrate growth rate by facilitating gas molecules solubilization. When SDS concentration increases, split and loss fraction increase initially and then decrease slightly, resulting in a decreased separation factor. The optimum concentration of SDS exists at the range of 100–300 ppm. As THF can be easily encaged in hydrate cavities, hydrate formation condition can be mitigated greatly with its existence. Additionally, THF can also strengthen hydrate formation. The THF effect on separation performance is related to feed gas components. CO₂ occupies the small cavities of type II hydrate prior to N₂. But the competitiveness of CO₂ and CH₄ to occupy cavities are quite fair. The variations of split fraction, loss fraction and separation factor depend on the concentration of THF added. The work in this paper has a positive role in flue gas CO₂ capture and natural gas de-acidification.     

Calcination and sintering characteristics of limestone under O2/CO2 combustion atmosphere

The O₂/CO₂ coal combustion technology is an innovative combustion technology that can control CO₂, SO₂ and NO_x emissions simultaneously. Calcination and sintering characteristics of limestone under O₂/CO₂ atmosphere were investigated in this paper. The pore size, the specific pore volume and the specific surface area of CaO calcined were measured by N₂ adsorption method. The grain size of CaO calcined was determined by XRD analysis. The specific pore volume and the specific surface area of CaO calcined in O₂/CO₂ atmosphere are less than that of CaO calcined in air at the same temperature. And the pore diameter of CaO calcined in O₂/CO₂ atmosphere is larger than that in air. The specific pore volume and the specific surface area of CaO calcined in O₂/CO₂ atmosphere increase initially with temperature, and then decline as temperature exceeds 1000 °C. The peaks of the specific pore volume and the specific surface area appear at 1000 °C. The specific surface area decreases with increase in the grain size of CaO calcined. The correlations of the grain size with the specific surface area and the specific pore volume can be expressed as L = 744.67 + 464.64 lg(1 / S) and L = − 608.5 + 1342.42 lg(1 / ε), respectively. Sintering has influence on the pore structure of CaO calcined by means of influencing the grain size of CaO.     

Development of new alumina-modified sorbents for CO2 sorption and regeneration at temperatures below 200 °C

A new regenerable alumina-modified sorbent was developed for CO₂ capture at temperatures below 200 °C. The CO₂ capture capacity of a potassium-based sorbent containing Al₂O₃ (KAlI) decreased during multiple CO₂ sorption (60 °C) and regeneration (200 °C) tests due to the formation of the KAl(CO₃)(OH)₂ phase, which could be converted into the original K₂CO₃ phase above 300 °C. However, the new regenerable potassium-based sorbent (Re-KAl(I)) maintained its CO₂ capture capacity during multiple tests even at a regeneration temperature of 130 °C. In particular, the CO₂ capture capacity of the Re-KAl(I)60 sorbent which was prepared by the impregnation of Al₂O₃ with 60 wt.% K₂CO₃ was about 128 mg CO₂/g sorbent. This excellent CO₂ capture capacity and regeneration property were due to the characteristics of the Re-KAl(I) sorbent producing only a KHCO₃ phase during CO₂ sorption, unlike the KAlI30 sorbent which formed the KHCO₃ and KAl(CO₃)(OH)₂ phases even at 60 °C. This result was explained through the structural effect of the support containing the KAl(CO₃)(OH)₂ phase which was prepared by impregnation of Al₂O₃ with K₂CO₃ in the presence of CO₂.     

Ca-based sorbent looping combustion for CO2 capture in pilot-scale dual fluidized beds

To demonstrate process feasibility of in situ CO₂ capture from combustion of fossil fuels using Ca-based sorbent looping technology, a flexible atmospheric dual fluidized bed combustion system has been constructed. Both reactors have an ID of 100 mm and can be operated at up to 1000 °C at atmospheric pressure. This paper presents preliminary results for a variety of operating conditions, including sorbent looping rate, flue gas stream volume, CaO/CO₂ ratio and combustion mode for supplying heat to the sorbent regenerator, including oxy-fuel combustion of biomass and coal with flue gas recirculation to achieve high-concentration CO₂ in the off-gas. It is the authors' belief that this study is the first demonstration of this technology using a pilot-scale dual fluidized bed system, with continuous sorbent looping for in situ CO₂ capture, albeit at atmospheric pressure. A multi-cycle test was conducted and a high CO₂ capture efficiency (> 90%) was achieved for the first several cycles, which decreased to a still acceptable level (> 75%) even after more than 25 cycles. The cyclic sorbent was sampled on-line and showed general agreement with the features observed using a lab-scale thermogravimetric analysis (TGA) apparatus. CO₂ capture efficiency decreased with increasing number of sorbent looping cycles as expected, and sorbent attrition was found to be another significant factor to be limiting sorbent performance.     

Effect of In, Ce and Bi dopings on sintering and dielectric properties of Ba(Zn1/3Nb2/3)O3 ceramics

In, Ce and Bi doped Ba(Zn_1/3Nb_2/3)O₃ (BZN) ceramics were prepared by conventional mixed oxide technique. In doping between 0.2 and 4.0 mol% increased the density of BZN at 1300 °C, Ce doping caused a decrease in density at 1250 °C. Levels of Bi₂O₃ up to 1.0 mol% had negative effect on densification, while high level doping could significantly improve the densification of the specimens. XRD of the samples indicated that In, Ce and Bi doping resulted in single phase formation at all concentrations, except 0.5 mol% Bi. SEM of Bi doped BZN indicated only single phase structure and Ce doping even at 0.2 mol% gave some secondary phases. In and Ce doping increased the dielectric constant from 41 to around 66 at 1 MHz. Bi doping decreased the dielectric constant to about 37 at 0.2 mol%, and then higher doping led to dielectric constant to increase to about 63.     

Long-term degradation of Ta2O5-doped Bi2O3 systems

Bismuth oxide in δ-phase is a well-known high oxygen ion conductor and can be used as an electrolyte for intermediate temperature solid oxide fuel cells (IT-SOFCs). 5-10 mol% Ta₂O₅ are doped into Bi₂O₃ to stabilize δ-phase by solid state reaction process. One Bi₂O₃ sample (7.5TSB) was stabilized by 7.5 mol% Ta₂O₅ and exhibited single phase δ-Bi₂O₃-like (type I) phase. Thermo-mechanical analyzer (TMA), X-ray diffractometry (XRD), AC impedance and high-resolution transmission electron microscopy (HRTEM) were used to characterize the properties. The results showed that holding at 800-850 °C for 1 h was the appropriate sintering conditions to get dense samples. Obvious conductivity degradation phenomenon was obtained by 1000 h long-term treatment at 650 °C due to the formation of α-Bi₂O₃ phase and Bi₃TaO₇, and 〈1 1 1〉 vacancy ordering in Bi₃TaO₇ structure.     

Electrochemical decomposition of CO2 and CO gases using porous yttria-stabilized zirconia cell

Electrochemical decomposition of CO₂ and CO gases using a porous cell of Ru-8 mol% yttria-stabilized zirconia (YSZ) anode/porous YSZ electrolyte/Ni–YSZ cathode system at 400–800 °C was studied by analyzing the flow rate and composition of outlet gas, current density, and phases and elementary distribution of the electrodes and electrolyte. A part of CO₂ gas supplied at 50 ml/min was decomposed to solid carbon and O₂ gas through the cell at the electric field strengths of 0.9–1.0 V/cm. The outlet gas at a flow rate of 3 ml/min included 61–63% CO₂ and 37–39% O₂ at 700–800 °C and the outlet gas at a flow rate of 50 ml/min included 73–96% (average 85%) CO₂ and 4–27% (average 15%) O₂ at 800 °C. On the other hand, the supplied CO gas was also decomposed to solid carbon, O₂ and CO₂ gases at 800 °C. The fraction of outlet gas at a flow rate of 50 ml/min during the CO decomposition at 800 °C for 5 h was 11–36% CO, 59–81% O₂ and 2–9% CO₂. The detailed decomposition mechanisms of CO₂ and CO gases are discussed. Both Ni metal in the cathode and porous YSZ grains under the DC electric field have the ability to decompose CO gas into solid carbon and O²⁻ ions or O₂ gas.     

Thermodynamic modeling of dealcoholization of beverages using supercritical CO2: Application to wine samples

The supercritical removal of ethanol from alcoholic beverages (brandy, wine, and cider) was studied using the GC-EoS model to represent the phase equilibria behavior of the CO₂ + beverage mixture. Each alcoholic drink was represented as the ethanol + water mixture with the corresponding ethanol concentration (35 wt% for brandy, 9-12 wt% for different wines and 6 wt% for cider). The thermodynamic modeling was based on an accurate representation of the CO₂ + ethanol and CO₂ + water binary mixtures, and the CO₂ + ethanol + water ternary mixture.The GC-EoS model was employed to simulate the countercurrent supercritical CO₂ dealcoholization of the referred beverages; the results obtained compared good with experimental data from the literature. Thus, the model was used to estimate process conditions to achieve an ethanol content reduction from ca. 10 wt% to values lower than 1 wt%. The model results were tested by carrying out several extraction assays using wine, in a 3 m height packed column at 308 K, pressures in the range of 9-18 MPa and solvent to wine ratio between 9 and 30 kg/kg.     

Mechanochemical synthesis of MgTa2O6 ceramic

MgTa₂O₆ powders were prepared by mechanochemical synthesis from MgO and Ta₂O₅ in a planetary ball mill in air atmosphere using steel vial and steel balls. High-energy ball milling gave nearly single-phase MgTa₂O₆ after 8 h of milling time. Annealing of high-energy milled powder at various temperatures (700–1200 °C) indicated that high-energy milling speed up the formation and crystallization of MgTa₂O₆ from the amorphous mixture. The powder derived from 8 h of mechanical activation gave a particle size of around 28 nm. Although at low-annealing temperatures the grain size was almost the same as-milled powder, the grain size increased with annealing temperature reaching to around 1–2 μm after annealing at 1200 °C for 8 h.     

Techno-economic evaluation of a PVAm CO2-selective membrane in an IGCC power plant with CO2 capture

Published data for an operating power plant, the ELCOGAS 315 MWe Puertollano plant, has been used as a basis for the simulation of an integrated gasification combined cycle process with CO₂ capture. This incorporated a fixed site carrier polyvinylamine membrane to separate the CO₂ from a CO-shifted syngas stream. It appears that the modified process, using a sour shift catalyst prior to sulphur removal, could achieve greater than 85% CO₂ recovery at 95 vol% purity. The efficiency penalty for such a process would be approximately 10% points, including CO₂ compression. A modified plant with CO₂ capture and compression was calculated to cost €2320/kW, producing electricity at a cost of 7.6 € cents/kWh and a CO₂ avoidance cost of about €40/tonne CO₂.     

Catalytic syngas production from greenhouse gasses: Performance comparison of Ru-Al2O3 and Rh-CeO2 catalysts

In this work, 3% Ru-Al₂O₃ and 2% Rh-CeO₂ catalysts were synthesized and tested for CH₄-CO₂ reforming activity using either CO₂-rich or CO₂-lean model biogas feed. Low carbon deposition was observed on both catalysts, which negligibly influenced catalytic activity. Catalyst deactivation during temperature programmed reaction was observed only with Ru-Al₂O₃, which was caused by metallic cluster sintering. Both catalysts exhibited good stability during the 70 h exposure to undiluted equimolar CH₄/CO₂ gas stream at 750 °C. By varying residence time in the reactor during CH₄-CO₂ reforming, very similar quantities of H₂ were consumed for water formation. Reverse water-gas shift (RWGS) reaction occurred to a very similar extent either with low or high WHSV values over both catalysts, revealing that product gas mixture contained near RWGS equilibrium composition, confirming the dominance of WGS reaction and showing that shortening the contact time would actually decrease the H₂/CO ratio in the syngas produced by CH₄-CO₂ reforming, as long as RWGS is quasi equilibrated. H₂/CO molar ratio in the produced syngas can be increased either by operating at higher temperatures, or by using a feed stream with CH₄/CO₂ ratio well above 1.     

Preparation of a highly microporous carbon from a carpet material and its application as CO2 sorbent

In order to increase the use of carpet wastes (pre- and/or post-consumer wastes), this work studies for the first time the preparation and characterisation of a microporous material from a commercial carpet (pile fiber content: 80% wool/20% nylon; primary and secondary backings: woven polypropylene; binder: polyethylene) and its application for CO₂ capture. The porous material was prepared from an entire carpet material using a standard chemical activation with KOH and then, characterised in terms of their porous structure and surface functional groups. Adsorption of CO₂ was studied using a thermogravimetric analyser at several temperatures (25-100 °C) and under different CO₂ partial pressures (i.e. pure CO₂ flow and a ternary mixture of 15% CO₂, 5% O₂ and 80% N₂). In order to examine the adsorbent regenerability, multiple CO₂ adsorption/desorption cycles were also carried out. The surface area and micropore volume of the porous adsorbent were found to be 1910.17 m² g^− 1 and 0.85 cm³ g^− 1, respectively. The CO₂ adsorption profiles illustrate that the maximum CO₂ capture on the sample was reached in less than 10 min. CO₂ adsorption capacities up to 8.41 wt.% and 3.37 wt.% were achieved at 25 and 70 °C, respectively. Thermal swing regeneration studies showed that the prepared adsorbent has good cyclic regeneration capacities.