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Two Developments in Cleaner Gas-Fired Power Generation

3 August 2007

Metcalfe
Use of LSCF tubes could lower the cost of carbon capture. Click to enlarge.

Two new technologies offer the potential for gas-fired power generation with lower CO2 and lower NOx emissions.

Engineers at the University of Newcastle and Imperial College London have developed tiny ceramic tubes that, when used in a power plant, could produce a stream of almost pure CO2, thereby enabling low-cost capture and commercial utilization. Researchers at Lawrence Berkeley National Laboratory and Solar Turbines have developed a low-swirl injector for turbines that can bring NOx emissions close to zero.

Low cost CO2 capture. The Newcastle University-Imperial College London team developed tubes of LSCF—Lanthanum-Strontium-Cobalt-Ferric Oxide, a material originally developed for use in solid oxide fuel cell cathodes. LSCF can filter oxygen out of the air. By burning fuel in pure oxygen, it is possible to produce a stream of almost pure carbon dioxide, which has commercial potential.

Conventional gas-fired power stations burn methane in a stream of air, producing a mixture of nitrogen and greenhouse gases including carbon dioxide and nitrogen oxides, which are emitted into the atmosphere. Separating the gases is not practical because of the high cost and large amount of energy needed to do so.

However, when air is blown around the outside of the LSCF tubes, oxygen is able to pass through the wall of the tube to the inside, where it combusts with methane gas that is being pumped through the centre of the tubes. Allowing only the oxygen component of air to reach the methane gas results in the production of almost pure carbon dioxide and steam, which can easily be separated by condensing out the steam as water. Crucially, LSCF is also resistant to corrosion or decomposition at typical power station operating temperatures of around 800 °C.

The oxygen-depleted air, which consists mainly of nitrogen, can be returned to the atmosphere with no harmful effects on the environment, while the carbon dioxide can be collected separately from the inside of the tubes after combustion.

The resulting stream of carbon dioxide could be piped to a processing plant for conversion into chemicals such as methanol.

An alternative would be to control the flow of air and methane so that only partial combustion took place. This would result in a flow of synthesis gas, a mixture of carbon monoxide and hydrogen, which can be converted into a variety of useful hydrocarbon chemicals.

The tubes of LSCF have been tested successfully in the laboratory. The Newcastle team is now carrying out further tests on the durability of the tubes to confirm their initial findings that they could withstand the conditions inside a power station combustion chamber for a reasonable length of time.

In theory the technology could also be applied to coal and oil-fired power stations, provided that the solid and liquid fuels were first converted into gas—albeit at additional cost.

The new combustion process has been developed and tested in the laboratory by Professor Ian Metcalfe, Dr Alan Thursfield and colleagues in the School of Chemical Engineering and Advanced Materials at Newcastle University, in collaboration with Dr Kang Li in the Chemical Engineering Department at Imperial College London. The research has been funded by the Engineering and Physical Sciences Research Council (EPSRC).

Details of the research and development project are published today (3 August 2007) simultaneously in two technical publications: Materials World and The Chemical Engineer. A series of research papers have also been published in academic journals and presented at conferences, including the 16th International Conference on Solid State Ionics in Shanghai in July 2007.

Lsilabeled
A prototype of the low-swirl injector. Fuel flows through the openings of the center channel. This simple design creates the low-swirl flow, with lower emissions of NOx the result.

Low NOx. An experimental gas turbine simulator equipped with an ultralow-emissions combustion technology called LSI (low-swirl injector) has been tested successfully using pure hydrogen as a fuel.

The low swirl injector is a mechanically simple device with no moving parts that imparts a mild spin to the gaseous fuel and air mixture that causes the mixture to spread out. The flame is stabilized within the spreading flow just beyond the exit of the burner. Not only is the flame stable, but it also burns at a lower temperature than that of conventional burners. The production of nitrogen oxides is highly temperature-dependent, and the lower temperature of the flame reduces emissions of nitrogen oxides to very low levels.

Natural gas-burning turbines with the low-swirl injector emit an order of magnitude lower levels of NOx than conventional turbines. Tests at Berkeley Lab and Solar Turbines showed that the burners with the LSI emit 2 parts per million of NOx (corrected to 15% oxygen), more than five times less than conventional burners.

A more significant benefit of the LSI technology is its ability to burn a variety of different fuels from natural gas to hydrogen and the relative ease to incorporate it into current gas turbine design—extensive redesign of the turbine is not needed. The LSI is being designed as a drop-in component for gas-burning turbine power plants.

The LSI technology, developed by Robert Cheng of the US Department of Energy’s Lawrence Berkeley National Laboratory, recently won a 2007 R&D 100 award from R&D magazine as one of the top 100 new technologies of the year.

The LSI principle defies conventional approaches. Combustion experts worldwide are just beginning to embrace this counter-intuitive idea. Principles from turbulent fluid mechanics, thermodynamics, and flame chemistry are all required to explain the science underlying this combustion phenomenon.

—Robert Chang

The Department of Energy’s Office of Electricity Delivery and Energy Reliability initially funded the development of the LSI for use in industrial gas turbines for on-site (i.e. distributed) electricity production. The purpose of this research was to develop a natural gas-burning turbine using the LSI’s ability to substantially reduce NOx emissions.

T70cutout
A cutaway view of Solar Turbines' Taurus 70 engine.

Robert Cheng, Berkeley Lab colleague David Littlejohn, and Kenneth Smith and Wazeem Nazeer from Solar Turbines Inc. of San Diego adapted the low-swirl injector technology to the Taurus 70 gas turbine that produces about seven MW of electricity. The team’s effort garnered them the R&D 100 honor. It is continuing the LSI development for carbon-neutral renewable fuels available from landfills and other industrial processes such as petroleum refining and waste treatments.

DOE’s Office of Fossil Energy is funding another project in which the LSI is being tested for its ability to burn syngas (a mixture of hydrogen and carbon monoxide) and hydrogen fuels in the FutureGen advanced IGCC plant (Integrated Gasification Combined Cycle). The intention of the FutureGen plant is to produce hydrogen from gasification of coal and sequester the carbon dioxide generated by the process. The LSI is one of several combustion technologies being evaluated for use in the 200+ MW utility-size hydrogen turbine that is a key component of the FutureGen plant.

The collaboration between Berkeley Lab and the National Energy Technology Laboratory (NETL) in Morgantown, WV, recently achieved the milestone of successfully test-firing an LSI unit using pure hydrogen as its fuel.

Because the LSI is a simple and cost-effective technology that can burn a variety of fuels, it has the potential to help eliminate millions of tons of carbon dioxide and thousands of tons of NOx from power plants each year.

Resources:

August 3, 2007 in Power Generation | Permalink | Comments (11) | TrackBack (0)

Comments

One hopes that this caliber technology becomes the base level for all new power plants burning carbon fuels. IGCC sounds highly promising if it can actually do what it claims. Long term problem with coal gasification project is the non-sustainable component. However as a relatively clean source of electricity and H2 - it seems good.

Posted by: gr | August 03, 2007 at 10:13 AM

The LCSF tubes apparently need high temperatures to work their magic. I wonder if they could be used to remove virtually all of the oxygen from the raw exhaust gas of a lean-burning ICE (diesel, CNG or stratified GDI). If so, a cheap regular three-way catalyst might be sufficient to meet emissions standards. A DPF may also be required when combusting diesel fuel, possibly upstream of the LCSF tube.

The pure oxygen produced would usually be vented into the atmosphere. However, during engine warm-up and transient acceleration, it might make sense to feed some of it back into the intake after intercooling in a stainless steel heat exchanger. Doping the fresh charge with extra oxygen would yield extra power during transients, with the higher exhaust temperatures reducing turbo lag. This would permit the use of a smaller, lighter, cheaper engine in LDV applications for which part load is the regular case. The extra NOx produced due to the oxygen doping would be taken care of by the three-way catalyst and a slightly rich mixture.

Posted by: Rafael Seidl | August 03, 2007 at 01:50 PM

Presumably the tube oxygen separator has a lower power requirement than the pressure swing zeolite method, but the article doesn't say how much. I also note that it envisions gasified coal which is also mentioned by some fuel cell researchers. However if the tests use lab quality methane that is a lot different to gas containing particulate and sulphur.

Posted by: Aussie | August 03, 2007 at 03:50 PM

With regard to the LSCF oxygen separator tubes, maybe someone can help me out. What I don't understand is this. If they have a tube which is permeable enough to oxygen at regular combustion temperatures for this purpose, why wouldn't they just use it as a standalone oxygen separator? The incoming air could be heated with waste heat using a heat recovery heat exchanger, pressure would be applied, and you would draw oxygen out of the tubes. This could then be fed to a separate turbine generator that burns gas/hydrocarbon fuel at a really high temperature, using ceramic turbine blades, giving unrivaled turbine efficiency (perhaps even better than fuel cell) without the traditional NOX barrier getting in the way. The CO2 is ready to sequester. NASA by the way has done some very interesting work in developing silicon carbide fiber composite turbine blades, so that part of the technology is available.

It looks to me like the connection between these two clever innovations is that they're direct competitors. Though in practice one would be used for radical new designs and the other for retrofits.

Posted by: P Schager | August 04, 2007 at 05:02 AM

Combustor technology isan art formas much as a Science i n my experience. There has been lots of money invested in precisely htis ara. I questioon whether thsi is rellynew ,but if it is counter-intuitive to current best-design practice, it may well be so. Technology advances in expected and unexpected ways.

Regarding the gas seperator, I wonder what the permeability is at working temperature. It would have to be pretty high to overcome the work inefficiencies in separating the O2 from N2. Not all N2 oxidizes; in most controlled combustion, If I am correct I suspect that only a tiny per centage does burn. It may still be better to seek out and control that tiny percentage than to separate 20% (O2), of the inbound air flow from its other 80% (N2).

Posted by: Stan Peterson | August 04, 2007 at 12:54 PM

P Schager

Excellent point.

Though I cannot claim to know the answer, I think, 800 degree C is too hot for intake air. Also, the technology of pure oxygen cobmustion is nor developed yet. Gases burns more vigorously in pure oxygen and produce more heat. A completely new engine needs to be developed to enable pure oxygen IC engine.

Posted by: SM | August 06, 2007 at 08:56 AM

Are there lower temp methods for separating the oxygen and nitrogen? I thought I have seen a poly cartridge tube. My interest is to reduce the nitrogen prior to going into a gasification process. The shell and tube method is much preferred if the pressure delta is not too high.

Regards, Toby Seiler

Posted by: Toby Seiler | August 06, 2007 at 02:19 PM

@ SM -

I'm not entirely sure your statement is correct. The amount of heat produced depends on both the available oxygen and the available fuel. If you have a global excess of oxygen, as you do in a diesel or stratified GDI engine, the unused portion merely ends up in the exhaust. Apart from the risk of accelerated oxidation, the only problem it causes there is that NOx cleanup becomes much harder; however, if there was no nitrogen in the intake gas, no NOx will be produced.

So, if pure oxygen were available and the engine construction sufficiently strong, you could achieve higher specific power (i.e. smaller and/or fewer cylinders). This may reduce engine weight and/or internal friction - presuming your oil is up to the job. For a given absolute power level, the total air mass flowing through the air filter would be comparable. However, the nitrogen would bypass the engine rather than pass through it.

The main reason you actually DO want a significant fraction of inert gas in the fresh charge is a different one: it slows down combustion. Near-isochoric heat release (cp. HCCI) is thermodynamically efficient but it also generates very high mechanical stresses and combustion noise levels. Unfortunately, the inert gas that's already in the atmosphere is nitrogen, which oxidizes at the high temperatures encountered in flame fronts.

Posted by: Rafael Seidl | August 07, 2007 at 09:19 AM

Thanks Rafael, I was wrong on the "more heat" part. My main point was, a new type of engine needs to be developed to use pure oxygen - which I think you confirmed.

Posted by: SM | August 10, 2007 at 09:33 AM

If pure oxygen is used in combustion for steam power plants, the combustion temperature can be much higher than with air. This can increase the efficiency by not needing to heat up and release hot nitrogen to the atmosphere as well as having a higher temperature to super-superheat the steam. It might even be useful to have a closed cycle steam compressor-turbine at low pressure and high temperature as a topping cycle. Several power plants attempted to use mercury vapor at the highest temperatures because steam at those temperatures has very high pressures and mercury does not. While new materials and technologies would prevent the release of any mercury vapor, such machines are now politically incorrect. Sodium vapor is much harder to deal with than mercury but its use in producing electricity with AMTEC cells (High pressure sodium forced through sodium ion conducting alumina at high temperatures.) would be facilitated by the higher temperature of pure oxygen combustion. Waste heat at very high temperatures from the AMTEC cells would be used to run regular steam turbines. Pure oxygen cannot be used in combustion turbines because the high temperatures would melt or otherwise destroy the combustion chamber and turbine blades. The oxygen could be diluted with steam or cooled recycled exhaust gas to lower the temperature as is done now with piston engines to lower the NOX production. Piston engines cannot withstand the temperature of the pure oxygen combustion either. The use of nitrous oxide, with its increased oxygen content stresses most engines as it is.

I am also interested to see if such tubes can produce pure oxygen gas.

Posted by: Henry Gibson | October 25, 2007 at 12:55 PM

This ceramic material allows for a simple zero pollution car to operate on the road and burn any liquid fuel. After combustion the exhaust gases are fed to a compressor that allows for the water to be condensed into a liquid and the carbon dioxide to be also condensed if the temperature is less than 88 Farenheit, 31 centigrade. There is enough space in a car to store the CO2 under pressure, even if not liquified, until it can be dropped off at a service station. Multiple small pressure tanks can be installed in free space and even pressure tubes could be used as structure elements. The tanks or tubes can be made of cheap steel or lighter materials if the expense can be tolerated. The water can be released or saved. Cooling the CO2 to liquid in hot climates may not be necessary. Evaporating the liquid water into dry air might provide some cooling.

The high temperature combustion can be used to operate a small stirling engine generator with heat pipes. Batteries with a ten mile capacity and high power are all that are needed; such batteries are made today even out of lead. Just a single extra Prius battery installed in a Prius with electronics that can put its full charge into the regular battery when needed would give the Prius 30 miles of extra full electric range.

The car could fuel up at service stations every 200 or 300 miles and drop off its CO2 while picking up more fuel. Any liquid or gaseous fuel could be used, but ordinary liquids like ethanol, vegetable oils, diesel, heating oil,colman lantern fuel, methanol and filtered used motor oil can all be used and compensated for by the car computer and oxygen sensor. No special qualities like octane rating or cetane rating or volatility are needed. There is no reason to make biodiesel, as the original oils can be used. A separate tank for some starting fuel could be useful. Even pure carbon nano particles suspended in a fluid could be a fuel. The fluid could be CO2.

A cheap simple steam car could be built to demonstrate the technology. A steam car with a vacuum insulated tank and home plug in electric heaters would have the instant take off capability. Fuel powered heaters could also keep the steam hot.

Fuel powered heaters are now built into some European diesel cars that are so efficient that enough heat is not produced to keep the car and engine warm at some cold temperatures. They might even have to invent exhaust gas heat recovery.... HG....

Posted by: Henry Gibson | October 25, 2007 at 03:40 PM

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