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ITM Technology for Carbon Capture on Natural Gas and Hybrid Power Systems John Repasky, David McCarthy, Phillip Armstrong, Michael Carolan © Air Products.

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Presentation on theme: "ITM Technology for Carbon Capture on Natural Gas and Hybrid Power Systems John Repasky, David McCarthy, Phillip Armstrong, Michael Carolan © Air Products."— Presentation transcript:

1 ITM Technology for Carbon Capture on Natural Gas and Hybrid Power Systems John Repasky, David McCarthy, Phillip Armstrong, Michael Carolan © Air Products and Chemicals, Inc All Rights Reserved 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,

2 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 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 Who is Air Products? 2 © Air Products and Chemicals, Inc All Rights Reserved

3 Air Products & CO 2 Solutions for the EOR Industry - Developing, financing, constructing, and operating CO 2 processing facilities - Helium Recovery Project - Port Arthur CO 2 Project - New H 2 S Removal Technology, NGL recovery Industrial CO 2 business in Americas & Europe - Recent purchase of EPCO CO 2 business CO 2 Capture R&D - Evaluation and development of broad range of CO 2 Capture Technologies - Pilot demonstration of CO 2 processing unit for oxyfuel combustion of coal at Vattenfalls research and development facility in Schwarze Pumpe, Germany 3 CO 2 Capture for EOR Port Arthur, Texas CO 2 Capture Pilot Germany Industrial CO 2 Europe, Americas © Air Products and Chemicals, Inc All Rights Reserved

4 Air Products Port Arthur CO 2 Project is approaching 1 million tonnes CO 2 90%+ CO 2 capture from 2 steam-methane reformers (Vacuum Swing Adsorption) ~30 MWe cogeneration unit to generate power and makeup steam ~925,000 tonnes CO 2 /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 CO 2 Capture On-stream: PA-II SMR – December 2012 PA-I SMR – March 2013 Full capacity achieved April 2013 © Air Products and Chemicals, Inc All Rights Reserved 4

5 ITM Technology targets low cost oxygen: enables pre-combustion & oxyfuel CO 2 capture Post-combustion capture Pre-combustion capture O 2 /CO 2 recycle (oxyfuel) combustion capture © Air Products and Chemicals, Inc All Rights Reserved 5

6 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 Air Products ITM Technology 6 © Air Products and Chemicals, Inc All Rights Reserved Ion Transport Membranes are a Platform Technology ITM Oxygen – Tonnage Oxygen Supply ITM Syngas – Tonnage Syngas/Hydrogen Supply

7 A proprietary ceramic membrane to separate oxygen from air – Inputs are high pressure air and heat/fuel – Outputs are oxygen and power/steam Unique technology gives high oxygen flux, high selectivity, and integrates well with high-temperature energy applications Oxygen What is ITM Oxygen ? ITM Oxygen Pressurized Air Heat/FuelPower/Steam 7 © Air Products and Chemicals, Inc All Rights Reserved

8 ITM Oxygen integrates well with power generation cycles AIR OXYGEN FUEL HEAT EXCHANGE ION TRANSPORT MEMBRANE HRSG STEAM OXYGEN BLOWER ELECTRIC POWER OXYGEN AIR 8 © Air Products and Chemicals, Inc All Rights Reserved

9 How does ITM technology reduce the cost of oxygen for carbon capture? Post-combustion capture Pre-combustion capture O 2 /CO 2 recycle (oxyfuel) combustion capture © Air Products and Chemicals, Inc All Rights Reserved 9

10 ITM Oxygen integrates oxygen production and power/steam generation Pre-combustion capture © Air Products and Chemicals, Inc All Rights Reserved IGCC/H2-fired GT CC Power Gen. ITM Oxygen Coal, NG Power Oxygen Syngas Gen. CO 2 Removal H 2 -rich fuel syngas CO 2 10

11 ITM Oxygen integrates oxygen production and power/steam generation O 2 /CO 2 recycle (oxyfuel) combustion capture © Air Products and Chemicals, Inc All Rights Reserved NGCC + Oxy-Coal Hybrid CC Power Gen. ITM Oxygen Coal, NG Power Oxygen Oxy-Comb. (e.g. Boiler) CO 2 Purif. CO 2 -rich flue gas NG Power CO 2 11

12 Compared ITM Oxygen with traditional air separation units (ASU) integrated into power plants Greenfield design basis included discussions with boiler and turbine manufacturers 12 The Electric Power Research Institute (EPRI) with Air Products and Worley Parsons conducted power plant assessments: IGCC & Oxy-combustion with carbon capture Oxy-combustion 800 MW gross SC PC boiler CO 2 capture percentage 87% 90% 75% ITM advantage relative to cryo ASU case Efficiency advantage 1.8 %pt 2.5 %pt 7.6 %pts Unit capital cost advantage 12 % 18 % 34 % LCOE* advantage 10 % 5 % 20 % * Levelized Cost of Electricity IGCC 765 MW gross IGCC F-class GT Reference publication: AIChE Spring Mtg, April/May © Air Products and Chemicals, Inc All Rights Reserved

13 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 13 Broad, multi-disciplinary team © Air Products and Chemicals, Inc All Rights Reserved

14 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 14 © Air Products and Chemicals, Inc All Rights Reserved 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.

15 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 15 © Air Products and Chemicals, Inc All Rights Reserved Intermediate-Scale Test Unit is in start-up for operation in ISTU Convent, LA U.S.A.

16 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 16 © Air Products and Chemicals, Inc All Rights Reserved ITM Vessel Intermediate-Scale Test Unit is in start-up for operation in ISTU Convent, LA U.S.A.

17 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 17 © Air Products and Chemicals, Inc All Rights Reserved Ceramic Fabrication scale-up is in commissioning to support Next Phase Energy Scale Development. CerFab Tooele, UT U.S.A.

18 ITM Oxygen: DOE Cooperative Program Phase 1: Technical Feasibility (0.1 TPD O 2 ) Phase 2: Prototype Testing (1 - 5 TPD O 2 ) Current activity Phases 3 and 5 are being conducted simultaneously Phase 3: Intermediate Scale Testing (100 TPD O 2 ) – 12 MW IGCC Phase 4: Reaction Driven Membranes Phase 5: Ceramic Module Fabrication to Supply 2000 TPD O 2 Facility Planning Next Phase: Energy Scale Development (2000 TPD O 2 ) - equivalent 250 MW IGCC or 110 MW oxycombustion 18 © Air Products and Chemicals, Inc All Rights Reserved ISTU and CerFab are critical steps to commercialize energy-scale ITM Oxygen. Actively pursuing early commercial opportunities.

19 © Air Products and Chemicals, Inc All Rights Reserved ITM Syngas is a revolutionary technology, which integrates oxygen production & syngas generation in a single unit 19

20 ITM Syngas is a revolutionary technology, which integrates oxygen production & syngas generation in a single unit Pre-combustion capture © Air Products and Chemicals, Inc All Rights Reserved NGCC/H2-fired GT CC Power Gen. ITM Syngas NG Power CO 2 Removal H 2 -rich fuel syngas CO 2 20

21 Air Products evaluated ITM Syngas to co-produce H 2 and CO 2 toward decarbonized fuel application 21 Compared ITM Syngas with conventional processes based on ATR/ASU to produce 150 to 760 MMscfd fuel-grade H 2. 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/H 2 /CO 2 production process. ITM Syngas showed thermal efficiency advantage of 3 percentage points. Reference publication: AIChE Spring Mtg, April © Air Products and Chemicals, Inc All Rights Reserved

22 ITM Syngas Development Program Phase 1: Laboratory-scale Materials and Membrane Development Phase 2: Two-levels of Scale-Up 27 Nm 3 /h, 24,000 scfd Process Development Unit (PDU) Current activity is focused on scale-up 280 Nm 3 /h, 0.25 million scfd Subscale Engineering Prototype (SEP) Phase 3: Early, Small, Commercial-Scale Unit Broad, multi-disciplinary team © Air Products and Chemicals, Inc All Rights Reserved 22

23 ITM Syngas Development Program Phase 1: Laboratory-scale Materials and Membrane Development Phase 2: Two-levels of Scale-Up 27 Nm 3 /h, 24,000 scfd Process Development Unit (PDU) Current activity is focused on scale-up 280 Nm 3 /h, 0.25 million scfd Subscale Engineering Prototype (SEP) Phase 3: Early, Small, Commercial-Scale Unit © Air Products and Chemicals, Inc All Rights Reserved 23 Commercial-size membranes have been operated through a wide range of conditions for over 150 days. Allentown, PA U.S.A.

24 ITM Syngas Development Program Phase 1: Laboratory-scale Materials and Membrane Development Phase 2: Two-levels of Scale-Up 27 Nm 3 /h, 24,000 scfd Process Development Unit (PDU) Current activity is focused on scale-up 280 Nm 3 /h, 0.25 million scfd Subscale Engineering Prototype (SEP) Phase 3: Early, Small, Commercial-Scale Unit © Air Products and Chemicals, Inc All Rights Reserved 24 Engineering Prototype will position ITM Syngas ready for early commercial operation Support sought for scale-up to the Engineering Prototype 28027

25 ITM Oxygen Clean energy Gasification: IGCC, Polygen, CtL, XtL, decarbonized fuel Oxy-combustion Traditional energy-intensive industrial production ITM Technology is Attractive across Broad Range of Applications ITM Syngas Hydrogen production Syngas for GTL Centralized de-carbonized fuel for distributed H 2 fuel Enables high degree of CO 2 capture © Air Products and Chemicals, Inc All Rights Reserved 25

26 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 shows significant benefit in both capital cost and energy savings across broad range of oxygen-based applications, including power generation with CCS © Air Products and Chemicals, Inc All Rights Reserved 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 26

27 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. 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-FC26-98FT 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. Acknowledgement 27 © Air Products and Chemicals, Inc All Rights Reserved

28 28 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 (Oxycombustion & IGCC Economics) -ITM Oxygen Technology: Scale-up Toward Clean Energy Applications, Intl Pittsburgh Coal Conf., Pittsburgh, PA, Oct (Program Update) ITM Syngas -Advances in ITM Technology for Syngas Production, Air Products/ Ceramatec, 10th Natural Gas Conversion Symposium (NGCS Doha 2013), Doha, Qatar, March (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 (Program Update & Economics) Phone: Fax: © Air Products and Chemicals, Inc All Rights Reserved

29 Phone: Fax: Thank you… tell me more © Air Products and Chemicals, Inc All Rights Reserved


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