ITM Oxygen Technology - United States Energy Association

Report
ITM Technology for
Carbon Capture on Natural Gas
and Hybrid Power Systems
John Repasky, David McCarthy,
Phillip Armstrong, Michael Carolan
Workshop on Technology Pathways Forward for Carbon
Capture & Storage on Natural Gas Power Systems
Organized by U.S. Energy Association
Supported by U.S. Dept. of Energy
Washington, DC, USA
April 22, 2014
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Who is Air Products?
 Merchant Gases
– Industrial, medical, and specialty gases
supplied to wide array of applications
 Tonnage Gases,
Equipment and Energy
– Industrial gases supplied via large
on-site facilities or pipeline systems;
equipment; technologies to serve
future industrial and energy markets
 Electronics and
Performance Materials
– Specialty and tonnage gases/chemicals,
services and equipment supplied to
electronics markets; performance
chemical solutions for a variety of
industries
FORTUNE 500 COMPANY ♦ $10.2 BILLION SALES FY13 ♦ SAFETY LEADER
21,600 Employees ♦ Operations over 50 countries ♦ Sales over 100 countries
Production Operator, Equipment & Plant Sales, Pipelines & Distribution
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Air Products & CO2
CO2 Capture for EOR
Port Arthur, Texas
 Solutions for the EOR Industry
- Developing, financing, constructing, and
operating CO2 processing facilities
- Helium Recovery Project
- Port Arthur CO2 Project
- New H2S Removal Technology, NGL recovery
Industrial CO2
Europe, Americas
 Industrial CO2 business in Americas &
Europe
- Recent purchase of EPCO CO2 business
 CO2 Capture R&D
- Evaluation and development of broad range of
CO2 Capture Technologies
- Pilot demonstration of CO2 processing unit for
oxyfuel combustion of coal at Vattenfall’s
research and development facility in Schwarze
Pumpe, Germany
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CO2 Capture Pilot
Germany
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Air Products Port Arthur CO2 Project
is approaching 1 million tonnes CO2
 90%+ CO2 capture from 2
steam-methane reformers
(Vacuum Swing Adsorption)
 ~30 MWe cogeneration unit
to generate power and
makeup steam
 ~925,000 tonnes CO2/year
Denbury “Green” pipeline
for EOR in Texas at West
Hastings oil field
 Total Project: $431 Million
DOE Share: $284 Million
(66%)
Source: Air Products and NETL
CO2 Capture On-stream:
PA-II SMR – December 2012
PA-I SMR – March 2013
Full capacity achieved April 2013
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Technology targets low cost oxygen:
enables pre-combustion & oxyfuel CO2 capture
Post-combustion
capture
Pre-combustion
capture
O2/CO2 recycle
(oxyfuel) combustion
capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Air Products’ ITM Technology
• Ion Transport Membranes (ITM) provide oxygen
at high-purity and high-flux
-
Non-porous mixed conducting
ceramic membranes
Operate at high temperature,
in the range 700 to 1000 C
• Started R&D in 1988
• Currently 90 U.S. Patents
and global equivalents
-
Materials and catalysts
Membrane and module structures
Process cycles
Applications and integrations
• U.S. DOE Cooperative Program since 1998
Ion Transport Membranes are a Platform Technology
• ITM Oxygen – Tonnage Oxygen Supply
• ITM Syngas – Tonnage Syngas/Hydrogen Supply
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
What is ITM Oxygen ?
A proprietary ceramic membrane to separate
oxygen from air
– Inputs are high pressure air and heat/fuel
– Outputs are oxygen and power/steam
Pressurized Air
Heat/Fuel
Oxygen
ITM Oxygen
Power/Steam
Unique technology gives high oxygen flux,
high selectivity, and integrates well with
high-temperature energy applications
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen integrates well with
power generation cycles
STEAM
OXYGEN
HRSG
AIR
ELECTRIC
POWER
OXYGEN
BLOWER
FUEL
‘AIR’
OXYGEN
HEAT
EXCHANGE
8
ION
TRANSPORT
MEMBRANE
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
How does ITM technology reduce the cost
of oxygen for carbon capture?
Post-combustion
capture
Pre-combustion
capture
O2/CO2 recycle
(oxyfuel) combustion
capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen integrates oxygen production
and power/steam generation
CO2
Coal,
NG
Syngas
Gen.
syngas
CO2
Removal
H2-rich
fuel
CC
Power
Gen.
Power
ITM
Oxygen
Oxygen
IGCC/H2-fired GT
Pre-combustion
capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen integrates oxygen production
and power/steam generation
CO2-rich
flue gas
Oxy-Comb.
Coal,
(e.g. Boiler)
NG
CO2
Purif.
CO2
Power
Oxygen
NG
CC
Power
Gen.
ITM
Oxygen
Power
NGCC + Oxy-Coal Hybrid
O2/CO2 recycle
(oxyfuel) combustion
capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
The Electric Power Research Institute (EPRI)
with Air Products and Worley Parsons
conducted power plant assessments:
IGCC & Oxy-combustion with carbon capture


Compared ITM Oxygen with traditional air separation
units (ASU) integrated into power plants
Greenfield design basis included discussions
with boiler and turbine manufacturers
IGCC
765 MWgross IGCC
F-class GT
CO2 capture percentage
87%
Oxy-combustion
800 MWgross
SC PC boiler
90%
ITM advantage relative to cryo ASU case
Efficiency advantage
1.8 %pt
2.5 %pt
Unit capital cost advantage
12 %
18 %
LCOE* advantage
10 %
5%
* Levelized Cost of Electricity
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Reference publication: AIChE Spring Mtg, April/May 2013.
75%
7.6 %pts
34 %
20 %
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
Broad, multi-disciplinary team
GE Energy
SOFCo EFS
(McDermott)
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
Over 1000 days of operation
have demonstrated oxygen
purity, oxygen flux, and
pressure/temperature cycling.
Commercial modules and
next generation components
continue to be tested.
Recently relocated from
Sparrows Point, MD to
Convent, LA U.S.A.
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
Intermediate-Scale
Test Unit is in start-up
for operation in 2014.
“ISTU”
Convent, LA U.S.A.
15
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
ITM Vessel
Intermediate-Scale
Test Unit is in start-up
for operation in 2014.
“ISTU”
Convent, LA U.S.A.
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
Ceramic Fabrication
scale-up is in
commissioning to
support Next Phase
Energy Scale
Development.
“CerFab”
Tooele, UT U.S.A.
17
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Oxygen: DOE Cooperative Program
• Phase 1: Technical Feasibility (0.1 TPD O2)
• Phase 2: Prototype Testing (1 - 5 TPD O2)
Current activity Phases 3 and 5 are being conducted simultaneously
• Phase 3: Intermediate Scale Testing (100 TPD O2) – 12 MW IGCC
• Phase 4: Reaction Driven Membranes
• Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O2 Facility
• Planning Next Phase: Energy Scale Development (2000 TPD O2)
- equivalent 250 MW IGCC or 110 MW oxycombustion
ISTU and CerFab
are critical steps
to commercialize
energy-scale ITM
Oxygen.
Actively pursuing
early commercial
opportunities.
18
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Syngas is a revolutionary technology,
which integrates oxygen production &
syngas generation in a single unit
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Syngas is a revolutionary technology,
which integrates oxygen production &
syngas generation in a single unit
CO2
NG
ITM
Syngas
syngas
CO2
Removal
H2-rich
fuel
CC
Power
Gen.
Power
NGCC/H2-fired GT
Pre-combustion
capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Air Products evaluated ITM Syngas to
co-produce H2 and CO2 toward
decarbonized fuel application
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
Compared ITM Syngas with
conventional processes based
on ATR/ASU to produce 150
to 760 MMscfd fuel-grade H2.

ITM Syngas showed potential for 30% capital cost
savings in the synthesis gas generation process
area and over 20% capital cost savings for the
overall synthesis gas/H2/CO2 production process.

ITM Syngas showed thermal efficiency advantage
of 3 percentage points.
Reference publication: AIChE Spring Mtg, April 2005.
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Syngas Development Program
• Phase 1: Laboratory-scale Materials and Membrane Development
• Phase 2: Two-levels of Scale-Up
• 27 Nm3/h, 24,000 scfd Process Development Unit (PDU)
Current activity is focused on scale-up
• 280 Nm3/h, 0.25 million scfd Subscale Engineering Prototype (SEP)
• Phase 3: Early, Small, Commercial-Scale Unit
Broad, multi-disciplinary team
U.S. DEPARTMENT OF
ENERGY
22
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Syngas Development Program
• Phase 1: Laboratory-scale Materials and Membrane Development
• Phase 2: Two-levels of Scale-Up
• 27 Nm3/h, 24,000 scfd Process Development Unit (PDU)
Current activity is focused on scale-up
• 280 Nm3/h, 0.25 million scfd Subscale Engineering Prototype (SEP)
• Phase 3: Early, Small, Commercial-Scale Unit
Commercial-size
membranes have
been operated
through a wide range
of conditions for over
150 days.
Allentown, PA U.S.A.
23
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Syngas Development Program
• Phase 1: Laboratory-scale Materials and Membrane Development
• Phase 2: Two-levels of Scale-Up
• 27 Nm3/h, 24,000 scfd Process Development Unit (PDU)
Current activity is focused on scale-up
• 280 Nm3/h, 0.25 million scfd Subscale Engineering Prototype (SEP)
• Phase 3: Early, Small, Commercial-Scale Unit
27
280
• Engineering Prototype will position ITM Syngas ready for
24
•
early commercial operation
Support sought for scale-up to the Engineering Prototype
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Technology is Attractive
across Broad Range of Applications
ITM Oxygen
ITM Syngas
• Clean energy
• Hydrogen production
• Gasification: IGCC, Polygen,
CtL, XtL, decarbonized fuel
• Syngas for GTL
• Oxy-combustion
• Centralized de-carbonized fuel
for distributed H2 fuel
• Traditional energy-intensive
industrial production
• Enables high degree of
CO2 capture
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
ITM Technology shows significant benefit
in both capital cost and energy savings
across broad range of oxygen-based applications,
including power generation with CCS
• ITM Oxygen integrates oxygen
production and power generation
• ITM Syngas is a revolutionary
technology that combines oxygen
production and syngas generation
in a single unit operation
• ITM Technology is well positioned to meet the needs
of clean energy applications
- We are actively pursuing early commercial opportunities
- Additional development supporters are welcome
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Acknowledgement
This technology development has been supported in part by the
U.S. Department of Energy under Contract No. DE-FC26-97FT96052
and 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
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.
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© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Thank you…
tell me more
ITM Oxygen
- “Ceramic and Coal: ITM Oxygen for Power Generation with Reduced
CO2-Emissions, Detailed Engineering Study Results”, Air Products/
EPRI/WorleyParsons, AIChE Spring Mtg, San Antonio, TX, April/May
2013. (Oxycombustion & IGCC Economics)
- “ITM Oxygen Technology: Scale-up Toward Clean Energy Applications”,
Intl Pittsburgh Coal Conf., Pittsburgh, PA, Oct 2012. (Program Update)
www.airproducts.com
ITM Syngas
- “Advances in ITM Technology for Syngas Production”, Air Products/
Ceramatec, 10th Natural Gas Conversion Symposium
(NGCS Doha 2013), Doha, Qatar, March 2013. (Program Update)
- “ITM Syngas: Ceramic Membrane Technology for Lower Cost
Conversion of Natural Gas”, Air Products/Chevron/Sasol, AIChE Spring
Mtg, San Antonio, TX, March 2010. (Program Update & Economics)
28
[email protected]
Phone: +1 610 481 4475
Fax: +1 610 706 7420
© Air Products and Chemicals, Inc. 2014. All Rights Reserved
Thank you…
tell me more
[email protected]
Phone: +1 610 481 4475
Fax: +1 610 706 7420
29
© Air Products and Chemicals, Inc. 2014. All Rights Reserved

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