Sequential capture of CO2 and SO2 in a pressurized TGA simulating FBC conditions

Four FBC-based processes were investigated as possible means of sequentially capturing SO2 and CO2. Sorbent performance is the key to their technical feasibility. Two sorbents (a limestone and a dolomite) were tested in a pressurized thermogravimetric analyzer (PTGA). The sorbent behaviors were explained based on complex interaction between carbonation, sulfation, and direct sulfation. The best option involved using limestone or dolomite as a SO2-sorbent in a FBC combustor following cyclic CO2 capture. Highly sintered limestone is a good sorbent for SO2 because of the generation of macropores during calcination/carbonation cycling.     

Steam reactivation of spent CaO-based sorbent for multiple CO2 capture cycles

This study examines steam reactivation of sorbent to improve the reversibility of multiple CaO-CO2 capture cycles. Experiments to obtain spent sorbent were performed in a tube furnace, and reactivation was achieved using steam in a pressurized reactor. Sorbent activity for CO2 capture was then tested in a thermogravimetric analyzer (TGA), in multi-cycle carbonation tests. After reactivation the sorbent had even better characteristics for CO2 capture than that of the natural sorbent. The average carbonation degree over 10 cycles for the reactivated sorbent approached 70%, significantly higher than for the original sorbent (35-40%). This means that the same sorbent may achieve effective CO2 capture over a large number of cycles, in the absence of other phenomena such as attrition. Partially sulfated sorbents may also be reactivated, but hydration itself is also hindered by sulfation.     

Fabrication of CaO-based sorbents for CO₂ capture by a mixing method

Three types of sorbent were fabricated using various calcium and support precursors via a simple mixing method, in order to develop highly effective, durable, and cheap CaO-based sorbents suitable for CO(2) capture. The sorption performance and morphology of the sorbents were measured in a thermogravimetric analyzer and a scanning electron microscopy, respectively. The experimental results indicate that cement is a promising low-cost support precursor for contributing to the enhancement of cyclic CO(2) sorption capacity, especially when organometallic calcium precursors were used. A sorbent (with 75% CaO content) made from calcium l-lactate hydrate and cement showed the highest CO(2) sorption capacity of 0.36 g of CO(2)/g of sorbent and its capacity decreased only slightly after 70 cycles of carbonation and calcination.     

Influence of high-temperature steam on the reactivity of CaO sorbent for CO₂ capture

Calcium looping is a high-temperature CO(2) capture technology applicable to the postcombustion capture of CO(2) from power station flue gas, or integrated with fuel conversion in precombustion CO(2) capture schemes. The capture technology uses solid CaO sorbent derived from natural limestone and takes advantage of the reversible reaction between CaO and CO(2) to form CaCO(3); that is, to achieve the separation of CO(2) from flue or fuel gas, and produce a pure stream of CO(2) suitable for geological storage. An important characteristic of the sorbent, affecting the cost-efficiency of this technology, is the decay in reactivity of the sorbent over multiple CO(2) capture-and-release cycles. This work reports on the influence of high-temperature steam, which will be present in flue (about 5-10%) and fuel (～20%) gases, on the reactivity of CaO sorbent derived from four natural limestones. A significant increase in the reactivity of these sorbents was found for 30 cycles in the presence of steam (from 1-20%). Steam influences the sorbent reactivity in two ways. Steam present during calcination promotes sintering that produces a sorbent morphology with most of the pore volume associated with larger pores of ～50 nm in diameter, and which appears to be relatively more stable than the pore structure that evolves when no steam is present. The presence of steam during carbonation reduces the diffusion resistance during carbonation. We observed a synergistic effect, i.e., the highest reactivity was observed when steam was present for both calcination and carbonation.     

Development of regenerable MgO-based sorbent promoted with K2CO3 for CO2 capture at low temperatures

To improve their CO2 absorption capacity, alkali-based sorbents prepared by impregnation and wet mixing method of potassium carbonate on supports such as activated carbon and MgO (KACI30, KACP30, KMgI30, and KMgP30), were investigated in a fixed bed reactor (C02 absorption at 50-100 degrees C and regeneration at 150-400 degrees C). Total CO2 capture capacities of KMgI30-500 and KMgP30-500 were 178.6 and 197.6 mg CO2/g sorbent, respectively, in the presence of 11 vol % H2O even at 50 degrees C. The large amount of CO2 capture capacity of KMgP30-500 and KMgI30-500 could be explained by the fact that MgO itself, as well as K2CO3, could absorb CO2 in the presence of water vapor even at low temperatures. In particular, water vapor plays an important role in the CO2 absorption of MgO and KMgI30-500 even at low temperatures below 60 degrees C, in marked contrast to MgO and CaO which can absorb CO2 at high temperatures. The CO2 capture capacity of the KMgI30-300 sorbent, however, was less than that of KMgI30-500 due to the formation of Mg(OH)2 which did not absorb CO2. MgO based-sorbents promoted with K2CO3 after CO2 absorption formed new structures such as K2Mg(CO3)2 and K2Mg(CO3)2 x 4(H2O), unlike KACI30 which showed only the KHCO3 crystal structure. The new Mg-based sorbents promoted with K2CO3 showed excellent characteristics in that it could satisfy a large amount of CO2 absorption at low temperatures, a high CO2 absorption rate, and fast and complete regeneration.     

Retention of arsenic and selenium compounds using limestone in a coal gasification flue gas

Volatile arsenic and selenium compounds present in coals may cause environmental problems during coal combustion and gasification. A possible way to avoid such problems may be the use of solid sorbents capable of retaining these elements from flue gases in gas cleaning systems. Lime and limestone are materials that are extensively employed for the capture of sulfur during coal processing. Moreover, they have also proven to have good retention characteristics for arsenic and selenium during combustion. The aim of this work was to ascertain whether this sorbent is also useful for retaining arsenic and selenium species in gases produced in coal gasification. The study was carried out in a laboratory-scale reactor in which the sorbent was employed as a fixed bed, using synthetic gas mixtures. In these conditions, retention capacities for arsenic may reach 17 mg g(-1) in a gasification atmosphere free of H2S, whereas the presence of H2S implies a significant decrease in arsenic retention. In the case of selenium, H2S does not influence retention which may reach 65 mg g(-1). Post-retention sorbent characterization, thermal stability, and water solubility tests have shown that chemical reaction is one of the mechanisms responsible for the capture of arsenic and selenium, with Ca(AsO2)2 and CaSe being the main compounds formed.     

SO2 retention by reactivated CaO-based sorbent from multiple CO2 capture cycles

This paper examines the reactivation of spent sorbent, produced from multiple CO2 capture cycles, for use in SO2 capture. CaO-based sorbent samples were obtained from Kelly Rock limestone using three particle size ranges, each containing different impurities levels. Using a thermogravimetric analyzer (TGA), the sulfation behavior of partially sulfated and unsulfated samples obtained after multiple calcination-carbonation cycles in a tube furnace (TF), following steam reactivation in a pressurized reactor, is examined. In addition, samples calcined/sintered under different conditions after hydration are also examined. The results show that suitably treated spent sorbent has better sulfation characteristics than that of the original sorbent. Thus for example, after 2 h sulfation, > 80% of the CaO was sulfated. In addition, the sorbent showed significant activity even after 4 h when > 95% CaO was sulfated. The results were confirmed by X-ray diffraction (XRD) analysis, which showed that, by the end of the sulfation process, samples contained CaSO4 with only traces of unreacted CaO. The superior behavior of spent reactivated sorbent appears to be due to swelling of the sorbent particles during steam hydration. This enables the development of a more suitable pore surface area and pore volume distribution for sulfation, and this has been confirmed by N2 adsorption-desorption isotherms and the Barrett-Joyner-Halenda (BJH) method. The surface area morphology of sorbent after reactivation was examined by scanning electron microscopy (SEM). Ca(OH)2 crystals were seen, which displayed their regular shape, and their elemental composition was confirmed by energy-dispersive X-ray (EDX) analysis. The improved characteristics of spent reactivated sorbent in comparison to the original and to the sorbent calcined under different conditions and hydrated indicate the beneficial effect of CO2 cycles on sorbent reactivation and subsequent sulfation. These results allow us to propose a new process for the use of CaO-based sorbent in fluidized bed combustion (FBC) systems, which incorporates CO2 capture, sorbent reactivation, and SO2 retention.     

Key factor in rice husk Ash/CaO sorbent for high flue gas desulfurization activity

Siliceous materials such as rice husk ash (RHA) have potential to be utilized as high performance sorbents for the flue gas desulfurization process in small-scale industrial boilers. This study presents findings on identifying the key factorfor high desulfurization activity in sorbents prepared from RHA. Initially, a systematic approach using central composite rotatable design was used to develop a mathematical model that correlates the sorbent preparation variables to the desulfurization activity of the sorbent. The sorbent preparation variables studied are hydration period, x1 (6-16 h), amount of RHA, x2 (5-15 g), amount of CaO, x3 (2-6 g), amount of water, x4 (90-110 mL), and hydration temperature, x5 (150-250 degrees C). The mathematical model developed was subjected to statistical tests and the model is adequate for predicting the SO2 desulfurization activity of the sorbent within the range of the sorbent preparation variables studied. Based on the model, the amount of RHA, amount of CaO, and hydration period used in the preparation step significantly influenced the desulfurization activity of the sorbent. The ratio of RHA and CaO used in the preparation mixture was also a significant factor that influenced the desulfurization activity of the sorbent. A RHA to CaO ratio of 2.5 leads to the formation of specific reactive species in the sorbent that are believed to be the key factor responsible for high desulfurization activity in the sorbent. Other physical properties of the sorbent such as pore size distribution and surface morphology were found to have insignificant influence on the desulfurization activity of the sorbent.     

Highly efficient CO2 sorbents: development of synthetic, calcium-rich dolomites

The reaction of CaO with CO(2) is a promising approach for separating CO(2) from hot flue gases. The main issue associated with the use of naturally occurring CaCO(3), that is, limestone, is the rapid decay of its CO(2) capture capacity over repeated cycles of carbonation and calcination. Interestingly, dolomite, a naturally occurring equimolar mixture of CaCO(3) and MgCO(3), possesses a CO(2) uptake that remains almost constant with cycle number. However, owing to the large quantity of MgCO(3) in dolomite, the total CO(2) uptake is comparatively small. Here, we report the development of a synthetic Ca-rich dolomite using a coprecipitation technique, which shows both a very high and a stable CO(2) uptake over repeated cycles of calcination and carbonation. To obtain such an excellent CO(2) uptake characteristic it was found to be crucial to mix the Ca(2+) and Mg(2+) on a molecular level, that is, within the crystalline lattice. For sorbents which were composed of mixtures of microscopic crystals of CaCO(3) and MgCO(3), a decay behavior similar to natural limestone was observed. After 15 cycles, the CO(2) uptake of the best sorbent was 0.51 g CO(2)/g sorbent exceeding the CO(2) uptake of limestone by almost 100%.     

Cycle development and design for CO2 capture from flue gas by vacuum swing adsorption

CO2 capture and storage is an important component in the development of clean power generation processes. One CO2 capture technology is gas-phase adsorption, specifically pressure (or vacuum) swing adsorption. The complexity of these processes makes evaluation and assessment of new adsorbents difficult and time-consuming. In this study, we have developed a simple model specifically targeted at CO2 capture by pressure swing adsorption and validated our model by comparison with data from a fully instrumented pilot-scale pressure swing adsorption process. The model captures nonisothermal effects as well as nonlinear adsorption and nitrogen coadsorption. Using the model and our apparatus, we have designed and studied a large number of cycles for CO2 capture. We demonstrate that by careful management of adsorption fronts and assembly of cycles based on understanding of the roles of individual steps, we are able to quickly assess the effect of adsorbents and process parameters on capture performance and identify optimal operating regimes and cycles. We recommend this approach in contrast to exhaustive parametric studies which tend to depend on specifics of the chosen cycle and adsorbent. We show that appropriate combinations of process steps can yield excellent process performance and demonstrate how the pressure drop, and heat loss, etc. affect process performance through their effect on adsorption fronts and profiles. Finally, cyclic temperature profiles along the adsorption column can be readily used to infer concentration profiles-this has proved to be a very useful tool in cyclic function definition. Our research reveals excellent promise for the application of pressure/vacuum swing adsorption technology in the arena of CO2 capture from flue gases.     

Novel regenerable sorbent for mercury capture from flue gases of coal-fired power plant

A natural chabazite-based silver nanocomposite (AgMC) was synthesized to capture mercury from flue gases of coal-fired power plants. Silver nanoparticles were engineered on zeolite through ion-exchange of sodium ions with silver ions, followed by thermal annealing. Mercury sorption test using AgMC was performed at various temperatures by exposing it to either pulse injection of mercury or continuous mercury flow. A complete capture of mercury by AgMC was achieved up to a capture temperature of 250 degrees C. Nano silver particles were shown to be the main active component for mercury capture by amalgamation mechanism. Compared with activated carbon-based sorbents, the sorbent prepared in this study showed a much higher mercury capture capacity and upper temperature limit for mercury capture. More importantly, the mercury captured by the spent AgMC could be easily released for safe disposal and the sorbent regenerated by simple heating at 400 degrees C. Mercury capture tests performed in real flue gas environment showed a much higher level of mercury capture by AgMC than by other potential mercury sorbents tested. In our mercury capture tests, the AgMC exposed to real flue gases showed an increased mercury capture efficiency than the fresh AgMC.     

Enhancement of fast CO2 capture by a nano-SiO2/CaO composite at Ca-looping conditions

In this paper we show the performance of a new CO(2) sorbent consisting of a dry physical mixture of a Ca-based sorbent and a SiO(2) nanostructured powder. Thermo-gravimetric analysis (TGA) performed at conditions close to the Ca-looping process demonstrate that the rate of CO(2) capture by the mixture is enhanced during the fast carbonation stage of practical interest in applications. Moreover, the residual capture capacity of the mixture is increased. SEM/EDX, physisorption, and XRD analyses indicate that there is a relevant interaction between the nanostructured SiO(2) skeleton and CaO at high temperatures, which serves to improve the efficiency of the transfer of CO(2) to small reactive pores as well as the stability of the sorbent pore structure.     

Thermal activation of CaO-based sorbent and self-reactivation during CO2 capture looping cycles

In this study, the thermal activation of different types of CaO-based sorbents was examined. Pretreatments were performed at different temperatures (800--1300 degrees C) and different durations (6--48 h) using four Canadian limestones. Sieved fractions of the limestones, powders obtained by grinding, and hydroxides produced following multiple carbonation/calcination cycles achieved in a tube furnace were examined. Pretreated samples were evaluated using two types of thermogravimetric reactors/ analyzers. The most important result was that thermal pretreatment could improve sorbent performance. In comparison to the original, pretreated sorbents showed better conversions over a longer series of CO2 cycles. Moreover, in some cases, sorbent activity actually increased with cycle number, and this effectwas especially pronounced for powdered samples preheated at 1000 degrees C. In these experiments, the increase of conversion with cycle number (designated as self-reactivation) after 30 cycles produced samples that were approximately 50% carbonated for the four sorbents examined here, and there appeared to be the potential for additional increase. These results were explained with the newly proposed pore--skeleton model. This model suggests, in addition to changes in the porous structure of the sorbent, that changes in the pore--skeleton produced during pretreatment strongly influence subsequent carbonation/ calcination cycles.     

Integration of calcium and chemical looping combustion using composite CaO/CuO-based materials

Calcium looping cycles (CaL) and chemical looping combustion (CLC) are two new, developing technologies for reduction of CO(2) emissions from plants using fossil fuels for energy production, which are being intensively examined. Calcium looping is a two-stage process, which includes oxy-fuel combustion for sorbent regeneration, i.e., generation of a concentrated CO(2) stream. This paper discuss the development of composite materials which can use copper(II)-oxide (CuO) as an oxygen carrier to provide oxygen for the sorbent regeneration stage of calcium looping. In other words, the work presented here involves integration of calcium looping and chemical looping into a new class of postcombustion CO(2) capture processes designated as integrated CaL and CLC (CaL-CLC or Ca-Cu looping cycles) using composite pellets containing lime (CaO) and CuO together with the addition of calcium aluminate cement as a binder. Their activity was tested in a thermogravimetric analyzer (TGA) during calcination/reduction/oxidation/carbonation cycles. The calcination/reduction typically was performed in methane (CH(4)), and the oxidation/carbonation stage was carried out using a gas mixture containing both CO(2) and O(2). It was confirmed that the material synthesized is suitable for the proposed cycles; with the very favorable finding that reduction/oxidation of the oxygen carrier is complete. Various schemes for the Ca-Cu looping process have been explored here that would be compatible with these new composite materials, along with some different possibilities for flow directions among carbonator, calciner, and air reactor.     

An electrochemical system for removing and recovering elemental mercury from a gas stream

The impending EPA regulations on the control of mercury emissions from the flue stacks of coal-burning electric utilities has resulted in the development of numerous advanced mercury control technologies such as sorbent injection and in-situ mercury oxidation. Although these technologies can effectively remove mercury from a flue stack they share, along with many other technologies, the common shortcoming of intermedia pollution transfer i.e. the traffic of mercury from the air phase to the solid phase and the subsequent generation of residue for landfill. This work addresses the need for an integrated system of mercury removal and recovery from flue stack gases and from the environment. The research explored the capture of elemental mercury from the gas phase at ambient temperature on an electrically conductive porous sorbent. The mercury loaded sorbent was regenerated at the anode in an electrochemical cell and the oxidized mercury recovered at the cathode as solid elemental mercury. Activated carbon cloth was selected as the most suitable sorbent as it had the highest mercury adsorption capacity of the sorbents tested and was electrically conductive. Direct and indirect electro-oxidation were shown to remove 95% and 100%, respectively, of the elemental mercury from the carbon cloth. After regeneration the carbon cloth was reused without any loss in mercury adsorption capacity. More than 99% of the mercury stripped from the cloth during regeneration was recovered at the cathode.     

Iron blast furnace slag/hydrated lime sorbents for flue gas desulfurization

Sorbents prepared from iron blast furnace slag (BFS) and hydrated lime (HL) through the hydration process have been studied with the aim to evaluate their reactivities toward SO2 under the conditions prevailing in dry or semidry flue gas desulfurization processes. The BFS/HL sorbents, having large surface areas and pore volumes due to the formation of products of hydration, were highly reactive toward SO2, as compared with hydrated lime alone (0.24 in Ca utilization). The sorbent reactivity increased as the slurrying temperature and time increased and as the particle size of BFS decreased; the effects of the liquid/solid ratio and the sorbent drying conditions were negligible. The structural properties and the reactivity of sorbent were markedly affected by the BFS/HL ratio; the sorbent with 30/70 ratio had the highest 1 h utilization of Ca, 0.70, and SO2 capture, 0.45 g SO2/g sorbent. The reactivity of a sorbent was related to its initial specific surface area (Sg0) and molar content of Ca (M(-1)); the 1 h utilization of Ca increased almost linearly with increasing Sg0/M. The results of this study are useful to the preparation of BFS/HL sorbents with high reactivity for use in the dry and semidry processes to remove SO2 from the flue gas.     

Capture of gas-phase arsenic oxide by lime: kinetic and mechanistic studies

Trace metal emission from coal combustion is a major concern for coal-burning utilities. Toxic compounds such as arsenic species are difficult to control because of their high volatility. Mineral sorbents such as lime and hydrated lime have been shown to be effective in capturing arsenic from the gas phase over a wide temperature range. In this study, the mechanism of interaction between arsenic oxide (As2O3) and lime (CaO) is studied over the range of 300-1000 degrees C. The interaction between these two components is found to depend on the temperature; tricalcium orthoarsenate (Ca3As2O8) is found to be the product of the reaction below 600 degrees C, whereas dicalcium pyroarsenate (Ca2As2O7) is found to be the reaction product in the range of 700-900 degrees C. Maximum capture of arsenic oxide is found to occur in the range of 500-600 degrees C. At 500 degrees C, a high reactivity calcium carbonate is found to capture arsenic oxide by a combination of physical and chemical adsorption. Intrinsic kinetics of the reaction between calcium oxide and arsenic oxide in the medium-temperature range of 300-500 degrees C is studied in a differential bed flow-through reactor. Using the shrinking core model, the order of reaction with respect to arsenic oxide concentration is found to be about 1, and the activation energy is calculated to be 5.1 kcal/mol. The effect of initial surface area of CaO sorbent is studied over a range of 2.7-45 m2/g using the grain model. The effect of other major acidic flue gas species (SO2 and HCl) on arsenic capture is found to be minimal under the conditions of the experiment.     

Estimates of increased black carbon emissions from electrostatic precipitators during powdered activated carbon injection for mercury emissions control

The behavior of mercury sorbents within electrostatic precipitators (ESPs) is not well-understood, despite a decade or more of full-scale testing. Recent laboratory results suggest that powdered activated carbon exhibits somewhat different collection behavior than fly ash in an ESP and particulate filters located at the outlet of ESPs have shown evidence of powdered activated carbon penetration during full-scale tests of sorbent injection for mercury emissions control. The present analysis considers a range of assumed differential ESP collection efficiencies for powdered activated carbon as compared to fly ash. Estimated emission rates of submicrometer powdered activated carbon are compared to estimated emission rates of particulate carbon on submicrometer fly ash, each corresponding to its respective collection efficiency. To the extent that any emitted powdered activated carbon exhibits size and optical characteristics similar to black carbon, such emissions could effectively constitute an increase in black carbon emissions from coal-based stationary power generation. The results reveal that even for the low injection rates associated with chemically impregnated carbons, submicrometer particulate carbon emissions can easily double if the submicrometer fraction of the native fly ash has a low carbon content. Increasing sorbent injection rates, larger collection efficiency differentials as compared to fly ash, and decreasing sorbent particle size all lead to increases in the estimated submicrometer particulate carbon emissions.     

Nanostructured sorbents for capture of cadmium species in combustion environments

The pathways of cadmium species to form a submicrometer-sized aerosol in a combustion system exhaust were established. Cadmium oxide was the predominant species formed in the experiments and resulted in particles of a mean size of 26-63 nm with number concentrations in the range of 2-8 x 10(6) cm(-3). Two different nanostructured sorbents, a solid montmorillonite (MMT) and an in situ generated agglomerated silica, were used for capture of the cadmium species. The MMT sorbent was not stable at 1000 degrees C, and structural changes resulted. MMT did not suppress nucleation of cadmium species and partially captured it by weak physisorption as established by the leachability tests. In contrast, the in situ generated silica nanostructured agglomerates had a high surface area, suppressed nucleation of cadmium species vapors, and chemisorbed them effectively resulting in a firm binding, as compared to the MMT sorbent. There is an optimal temperature-time relationship at which the capture process is expected to be most effective. The leaching efficiency under these conditions was less than 3.2%. The nanostructured silica agglomerate size can be tuned for effective capture in existing particle control devices.     

CO2-filling capacity and selectivity of carbon nanopores: synthesis, texture, and pore-size distribution from quenched-solid density functional theory (QSDFT)

Porous carbons synthesized by KOH activation of petroleum coke can have high surface areas, over 3000 m(2)/g, and high CO(2) sorption capacity, over 15 wt % at 1 bar. This makes them attractive sorbents for carbon capture from combustion flue gas. Quenched solid density functional theory (QSDFT) analysis of high-resolution nitrogen-sorption data for such materials leads to the conclusion that it is the pores smaller than 1 nm in diameter that fill with high-density CO(2) at atmospheric pressure. Upon increasing pressure, larger and larger pores are filled, up to about 4 nm at 10 bar. An ideal CO(2)/N(2) selectivity of such carbon materials tends to decrease substantially upon increasing pressure, for example, from about 8-10 at 1 bar to about 4-5 at 10 bar. All in all, this work confirms the robust CO(2)-filling properties of porous carbon sorbents, their low-pressure selectivity advantages, and points to the critical role of <1 nm pores that can be controlled with activation conditions.