AndreaBozzo/ceres-open-data-index huggingface dataset:
Task 6.5 - Gas Separation and Hot-Gas Cleanup

Catalytic gasification of coal to produce H{sub 2}- and CH{sub 4}-rich gases for consumption in molten carbonate fuel cells is currently under development; however, to optimize the fuel cell performance and extend its operating life, it is desired to separate as much of the inerts (i.e., CO{sub 2} and N{sub 2}) and impurities (i.e., H{sub 2}S and NH{sub 3}) as possible from the fuel gas before they enter the fuel cell. In addition, the economics of the integrated gasification combined cycle (IGCC) can be improved by separating as much of the hydrogen as possible from the fuel, since hydrogen is a high-value product. One process currently under development by the Energy & Environmental Research Center (EERC) for accomplishing this gas separation and hot-gas cleanup involves gas separation membranes. These membranes are operated at temperatures as high as 800 C and pressures up to 300 psig. Some of these membranes can have very small pores (30-50 {angstrom}), which inefficiently separate the undesired gases by operating in the Knudsen diffusion region of mass transport. Other membranes with smaller pore sizes (&lt;5 {angstrom}) operate in the molecular sieving region of mass transport phenomena, Dissolution of atomic hydrogen into thin metallic membranes made of platinum and palladium alloys is also being developed. Technological and economic issues that must be resolved before gas separation membranes are commercially viable include improved gas separation efficiency, membrane optimization, sealing of membranes in pressure vessels, high burst strength of the ceramic material, pore thermal stability, and material chemical stability. Hydrogen separation is dependent on the temperature, pressure, pressure ratio across the membrane, and ratio of permeate flow to total flow. For gas separation under Knudsen diffusion, increasing feed pressure and pressure ratio across the membrane should increase gas permeability; decreasing the temperature and the permeate-to-total flow ratio should also increase gas permeability. In the molecular sieving regime of mass transport, the inlet pressure and pressure ratio should have no effect on gas permeability, while increasing temperature should increase permeability.

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Selective methane oxidation over promoted oxide catalysts. Quarterly report, September--November, 1994

Experimental research in the direct conversion of methane to methanol using a double bed reactor and with gaseous steam as cofeed with the CH{sub 4}/air reactant mixture continued during this quarter in order to improve the methanol space time yield. Work was carried out along several pathways that included a stability test of the second bed catalyst 1%V{sub 2}O{sub 5}/SiO{sub 2} that yielded up to 100 g methanol/kg cat/hr and investigation of the effect of pressure on methanol yields. Redox dopants were put onto several metal oxide supports in an attempt to find better second bed catalysts. A catalyst that was reasonably selective towards oxygenates was obtained when SiO{sub 2} was used as the support and low quantities of Fe or Cu were utilized. Attempts were also made to incorporate alkali ions into the catalysts to improve the surface hydrolyzability. Experiments were carried out to examine the effect of pressure and temperature on the oxygenate productivity over a double-layered catalyst bed of 0.1 g 1 wt% SO{sub 4}{sup 2{minus}}/Sr/La{sub 2}O{sub 3} as the first bed and 0.1 g 1 wt% V{sub 2}O{sub 5}/SiO{sub 2} as the second bed without H{sub 2}O cofeed in a glass-lined tubular down-flow reactor at pressures of 0.1--3.2 MPa (14.7--460 psig), temperatures of 450--500 C, and with a reactant flow rate having a ratio of CH{sub 4}/air = 150/50 ml/min. Reaction products observed were methanol, formaldehyde, carbon dioxide, acetylene, ethylene, and ethane. The overall activity of the catalyst increased at low pressures and high temperature. However, testing at low temperature and high pressure was found to favor methanol production.

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Development of a natural gas systems analysis model (GSAM). Annual report, January 1994--January 1995

The objective of GSAM development is to create a comprehensive, non-proprietary, microcomputer model of the North American natural gas system. GSAM explicitly evaluates the key components of the system, including the resource base, exploration and development practices, extraction technology performance and costs, project economics, transportation costs and restrictions, storage, and end-use. The primary focus is the detailed characterization of the resource base at the reservoir and sub-reservoir level. This disaggregation allows direct evaluation of alternative extraction technologies based on discretely estimated, individual well productivity, required investments, and associated operating costs. GSAM`s design allows users to evaluate complex interactions of current and alternative future technology and policy initiatives as they directly impact the gas market. Key activities completed during the past year include: conducted a comparative analysis of commercial reservoir databases; licensed and screened NRG Associates Significant Oil and Gas Fields of the US reservoir database; developed and tested reduced form reservoir model production type curves; fully developed database structures for use in GSAM and linkage to other systems; developed a methodology for the exploration module; collected and updated upstream capital and operating cost parameters; completed initial integration of downstream/demand models; presented research results at METC Contractor Review Meeting; conducted other briefings for METC managers, including initiation of the GSAM Environmental Module; and delivered draft topical reports on technology review, model review, and GSAM methodology.

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A high temperature precision amplifier

A precision operational amplifier has been developed for instrumentation applications in which the circuitry must operate in ambient temperatures as high as 200 C. At 200 C the amplifier maintains an input offset voltage and current of less than 200 {mu}V and 1 nA respectively, a gain bandwidth product of 2.2 MHz, and a slew rate of 5.4 V/{mu}S. The amplifier is fabricated in a standard CMOS process and consumes 5.5 mW of power at a supply voltage of 5 V. A continuous time auto-zeroed amplifier topology is used to achieve the low offset voltage levels. At high temperatures the leakage currents of the sample and hold switches used to achieve auto-zeroing degrade the offset correction voltages stored on the hold capacitors. This degradation is reduced by using large external hold capacitors and by minimizing the diffusion area of the switches through the use of a doughnut shaped layout. The effect of the voltage degradation is reduced by sensing the offset correction voltage with a low sensitivity differential auxiliary input stage. A new input switch topology is used to reduce the amplifier`s input offset current at high temperatures.

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Project Calcium

Fouling problems in utility boilers have been classified into two principal types: high-temperature and low-temperature fouling. A multiclient-sponsored program was initiated at the Energy and Environmental Research Center (EERC) to better understand the causes of low-temperature fouling when burning high-calcium western US coals. The goals of Project Calcium were to define the low-temperature deposition problem, identify the calcium-based components that are responsible for the formation of the deposits, develop ways to predict their formation, and identify possible methods to mitigate the formation of these deposits. To achieve the goals of Project Calcium, detailed sampling of utility boilers and laboratory-scale studies coupled with state-of-the-art methods to determine the inorganic components in coals and coal ash-derived materials were conducted. Boiler Sampling was also performed. The work involved sampling coal, entrained ash, deposits and slags from five full-scale utility boilers combined with detailed advanced characterization of the materials. The results of this work aided in identifying the key phenomena to focus the laboratory studies and in model verification. Field testing was conducted at three utilities.

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Utilization of lightweight materials made from coal gasification slags. Quarterly report, September--November 1994

Coal gasification technologies are finding increasing commercial applications for power generation or production of chemical feedstocks. The integrated-gasification-combined-cycle coal conversion process has been demonstrated to be a clean, efficient, and environmentally acceptable method of generating power. However, the gasfication process produces relatively large quantities of a solid waste termed slag. Regulatory trends with respect to solid waste disposal, landfill development costs, and public concern make utilization of slag a high-priority issue. Therefore, it is imperative that slag utilization methods be developed, tested, and commercialized in order to offset disposal costs. In previous projects, Praxis investigated the utilization of ``as-generated`` slags for a wide variety of applications in road construction, cement and concrete production, agricultural applications, and landfill. We determined that it would be extremely difficult for ``as-generated`` slag to find acceptance in the marketplace even at no cost because the materials it could replace were abundantly available at very low cost. It became apparent that a more promising approach would be to develop a variety of value-added products from slag that would meet specific industry requirements. This approach was made feasible by the discovery that slag could be made into a lightweight material by heating it to between 1600 and 1900{degree}F in a kiln, which indicated the potential for using such materials as substitutes for lightweight aggregates. Between 1987 and 1993, the technologies to produce these materials from slag were developed by Praxis with funding from the Electric Power Research Institute, Illinois Clean Coal Institute, and internal resources.

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Production of mild gasification coproducts

In summary, the co-product production runs performed by the SGI Development Center yielded sufficient simulated PDF (process derived fuel) and CDL (coal derived liquid) to meet the production needs for each of the four coals. The LFC Process appears to be an attractive method for upgrading all of the coals except for the Knife River Coal because of its limited yield and difficulty in processing. The Buckskin coal appears to be a slightly stronger candidate for upgrading than the other three coals because it has the greatest CDL yield and a more than 50% increase in heating value from ROM to PDF. (LFC processing of Usibelli and Sarpy Creek coal produces more PDF, but the heating value increase is less and the oil yields are low. Processing Knife River coal produces much less PDF but a greater heating value increase because of its higher moisture content). Finally, in all cases, the LFC Process removed significant percentage of the organic sulfur, clearly demonstrating its coal cleaning potential.

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High-volume, high-value usage of Flue Gas Desulfurization (FGD) by-products in underground mines Phase 1: Laboratory investigations. Quarterly report, July 1994--September 1994

During the quarter a second series of samples were collected and partially characterized chemically and mineralogically. The samples were collected at the disposal site operated by Freeman United Coal Co. The second collection was necessary because of deterioration due to hydration of the original samples. A study of the hydration characteristics was completed during the quarter. Important reactions included the immediate formation of ettringite and portlandite. The hydration and transformation was found to be a slow process. A second phase of gypsum formation from ettringite deterioration was identified. The slow hydration of anhydrite with its resultant swell is a potential problem which will be addressed further. Geotechnical characterization, during the quarter included completion of the preliminary characterization, analysis of the findings, experimentation with sample preparation for the final characterization/mix design, and design of the final experimental program. The analysis of the coals collected during the core drilling and hydrologic planning were completed. Also during the quarter a meeting was held with representatives of the shotcrete industry to discuss transport systems for emplacement. The pros and cons of pneumatic and hydraulic systems were discussed and plans formulated for further investigations.

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Advanced sulfur control concepts for hot gas desulfurization technology. Quarterly report, October--December 1994

The goal is the development of simpler and economically superior processing of regenerable sorbents used for control of hydrogen sulfide in hot, high-pressure gas streams in advanced power generating systems. The improved processing will produce an elemental sulfur byproduct. Progress during the past quarter was limited by delays in identifying an appropriate analytical instrument for measuring the concentration of sulfur species (S{sub x}(g), H{sub 2}S, and SO{sub 2} in the regeneration product gas. The ability to carry out this analysis on a real-time basis is an important component of the overall project and we feel that a satisfactory gas analysis procedure should be available before forging ahead with other experimental activities. The primary accomplishment, therefore, was the completion and submission of the Task 3 Project Plan. This plan, which assumed a satisfactory solution to sulfur analysis problem, is included in this quarterly report.

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Analysis/control of in-bed tube erosion phenomena in the fluidized bed combustion (FBC) system. Technical progress report No. 9, [October 1, 1994--December 31, 1994]

This technical report summarizes the research work performed and progress achieved during the period of October 1, 1994 to December 31, 1994. The characteristics of anti-erosion remedies and mechanism for in-bed in FBC were discussed to provide the basic design guidelines for anti-erosion devices. One of the anti-erosion remedies currently operate the basic principle of creating a protective stagnant layer of solids to against incoming high velocity of solid particles. This stagnant layer of solid is goal of breaking up the local flow patterns at eroding tube surfaces. This principle is embodied by designing of antierosion studs, pins, fins, and baffles. By attaching a number of studs with a sufficient stud-to-stud distance to avoid the bridging of solid particles, tube wastage can be retarded to prolong the boiler tube life. These devices will be used for the measurement of material wastage in the laboratory-scale FBC.

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Hot coal gas desulfurization with manganese based sorbents. Quarterly report, June--September 1994

The focus of work being performed on hot coal gas desulfurization at the Morgantown Energy Technology Center is primarily in the use of zinc titanate sorbents; however, prior studies indicated that an alternate sorbent, manganese dioxide-containing ore in mixture with alumina (75 wt% ore   25 wt% Al{sub 2}O{sub 3}) appears to be a strong contender to zinc-based sorbents. Manganese, for example, has a lower vapor pressure in the elemental state than zinc; hence, it is not as likely to undergo zinc-depletion from the sorbent surface upon loading and regeneration cycles. Also manganese oxide is less readily reduced to the elemental state than iron; hence, the range of reduction potentials for oxygen is somewhat greater than for zinc ferrite. In addition, thermodynamic analysis of the manganese-oxygen-sulfur system shows it to be less amenable to sulfation than zinc ferrite. Also manganese chlorides are much less stable and volatile than zinc chlorides. Potential also exists for utilization of manganese at higher temperatures than zinc ferrite or zinc titanate. This Eighth Quarterly Report documents progress in pelletizing and testing via thermo-gravimetric analysis of individual pellet formulations of manganese ore/alumina combinations and also manganese carbonate/alumina with two binders, dextrin and bentonite.

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Advanced turbine systems program conceptual design and product development. Annual report, August 1993--July 1994

This Yearly Technical Progress Report covers the period August 3, 1993 through July 31, 1994 for Phase 2 of the Advanced Turbine Systems (ATS) Program by Solar Turbines Incorporated under DOE Contract No. DE-AC421-93MC30246. As allowed by the Contract (Part 3, Section J, Attachment B) this report is also intended to fulfill the requirements for a fourth quarterly report. The objective of Phase 2 of the ATS Program is to provide the conceptual design and product development plan for an ultra-high efficiency, environmentally superior and cost-competitive industrial gas turbine system to be commercialized in the year 2000. During the period covered by this report, Solar has completed three of eight program tasks and has submitted topical reports. These three tasks included a Project Plan submission of information required by NEPA, and the selection of a Gas-Fueled Advanced Turbine System (GFATS). In the latest of the three tasks, Solar`s Engineering team identified an intercooled and recuperated (ICR) gas turbine as the eventual outcome of DOE`s ATS program coupled with Solar`s internal New Product Introduction (NPI) program. This machine, designated ``ATS50`` will operate at a thermal efficiency (turbine shaft power/fuel LHV) of 50 percent, will emit less than 10 parts per million of NOx and will reduce the cost of electricity by 10 percent. It will also demonstrate levels of reliability, availability, maintainability, and durability (RAMD) equal to or better than those of today`s gas turbine systems. Current activity is concentrated in three of the remaining five tasks a Market Study, GFATS System Definition and Analysis, and the Design and Test of Critical Components.

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Advanced turbine systems program conceptual design and product development. Quarterly report, August--October 1994

This is a quarterly report on the Westinghouse Electric Corporation Advanced Turbine Systems Program--conceptual design and product development. The topics of the report include the management plan, National Energy Policy Act, selection of natural gas-fired advanced turbine systems, selection of coal-fired advanced turbine systems, market study, systems definition and analysis, design and test of critical components, and plans for the next reporting period.

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Advanced Turbine Systems program conceptual design and product development. Quarterly report, February--April 1994

Task 8.5 (active clearance control) was replaced with a test of the 2600F prototype turbine (Task 8.1T). Test 8.1B (Build/Teardown of prototype turbine) was added. Tasks 4 (conversion of gas-fired turbine to coal-fired turbine) and 5 (market study) were kicked off in February. Task 6 (conceptual design) was also initiated. Task 8.1 (advanced cooling technology) now has an approved test plan. Task 8.4 (ultra low NOx combustion technology) has completed the code development and background gathering phase. Task 8.6 (two-phase cooling of turbine vanes) is proceeding well; initial estimates indicate that nearly 2/3 of required cooling flow can be eliminated.

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Disposal of fluidized bed combustion ash in an underground mine to control acid mine drainage and subsidence. Progress report, September 1, 1994--November 30, 1994

During Phase I (first 18 months) the project is segregated into four areas of reporting: (A) Grout Formulation, (B) Grout Characterization, (C) Water Quality Monitoring, (D) Subsidence Control & Contaminant Transport. The first component involves formulating a grout mixture with appropriate flowability and strength (flow and strength requirements will be set by other components) to be used in filling complex mine voids. The Grout Characterization component will determine the flowability characteristics of the formulated grout and model the flow of the grout filling the mine void. The Water Quality component involves background monitoring of water quality and precipitation at the Phase III (Longridge) mine site. The last component involves evaluating the strength requirements and the migration of contaminants through the candidate grouts. This report separately discusses progress on all components of the program in order of project subtask. The subtasks are arranged according to the Network Diagram on the following pages. Progress for each subtask can be seen in the Gantt Chart following the Network Diagram.

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Direct methane conversion to methanol. Annual report, October 1993--September 1994

We proposed to demonstrate the effectiveness of a catalytic membrane reactor (a ceramic membrane combined with a catalyst) to selectively produce methanol by partial oxidation of methane. Methanol is used as a chemical feedstock, gasoline additive, and turbine fuel. Methane partial oxidation using a catalytic membrane reactor has been determined as one of the promising approaches for methanol synthesis from methane. In the original proposal, the membrane was used to selectively remove methanol from the reaction zone before carbon oxides form, thus increasing the methanol yield. Methanol synthesis and separation in one step would also make methane more valuable for producing chemicals and fuels. However, all the membranes tested in this laboratory lost their selectivity under the reaction conditions. A modified non-isothermal, non-permselective membrane reactor then was built and satisfactory results were obtained. The conversion and selectivity data obtained in this laboratory were better than that of the most published studies.

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A calcium oxide sorbent process for bulk separation of carbon dioxide. Final report

The expected commercialization of coal gasification technology in the US and world-wide will create a need for advanced gas purification and separation processes capable of operating at higher temperatures and in more hostile environments than is common today. For example, a high-temperature, high-pressure process capable of separating CO{sub 2} from coal-derived gas may find application in purifying synthesis gas for H{sub 2}, NH{sub 3}, or CH{sub 3}OH production. High temperature CO{sub 2} removal has the potential for significantly improving the operating efficiency of integrated gasification-molten carbonate fuel cells for electric power generation. This study proved the technical feasibility of a CO{sub 2}-separation process based upon the regenerable noncatalytic gas-solid reaction between CaO and CO{sub 2} to form CaCO{sub 3}. Such a process operating at 650{degree}C and 15 atm with 15% CO{sub 2}, in the feed gas has the potential for removing in excess of 99% of the CO{sub 2} fed. Selection of a sorbent precursor which, upon calcination, produces high-porosity CaO is important for achieving rapid and complete reaction. The addition of magnesium to the sorbent appears to improve the multicycle durability at a cost of reduced CO{sub 2} capacity per unit mass of sorbent. When CO and H{sub 2}O were present in the feed gas, the water gas shift and carbonation reactions occurred simultaneously, thus providing a potential alternate route for the production of H{sub 2} from coal-derived gas. Material and energy balances based on an Aspen simulation were conducted by METC personnel. This phase of the study identified process related problems which must be addressed before the combined shift-carbonation process could become commercial. Other applications of the combined shift-carbonation process, in addition to the production of high purity H{sub 2}, have been suggested.

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