Techno-economic assessment of polymer membrane systems for postcombustion carbon capture at coal-fired power plants

Penetrant-induced plasticization in microporous polymer membranes

Penetrant-induced plasticization has prevented the industrial deployment of many polymers for membrane-based gas separations. With the advent of microporous polymers, new structural design features and unprecedented property sets are now accessible under controlled laboratory conditions, but property sets can often deteriorate due to plasticization. Therefore, a critical understanding of the origins of plasticization in microporous polymers and the development of strategies to mitigate this effect are needed to advance this area of research. Herein, an integrative discussion is provided on seminal plasticization theory and gas transport models, and these theories and models are compared to an exhaustive database of plasticization characteristics of microporous polymers. Correlations between specific polymer properties and plasticization behavior are presented, including analyses of plasticization pressures from pure-gas permeation tests and mixed-gas permeation tests for pure polymers and composite films. Finally, an evaluation of common and current state-of-the-art strategies to mitigate plasticization is provided along with suggestions for future directions of fundamental and applied research on the topic.

A critical review in recent progress of hollow fiber membrane contactors for efficient CO2 separations

Among wide range of membrane-based operations, membrane contactors, as they reify comparatively modern membrane-based mechanism are gaining quite an attention in both pilot and industrial scales. In recent literature, carbon capture is one of the most researched applications of membrane contactors. Membrane contactors have the potential to minimize the energy consumption and capital cost of traditional CO₂ absorptions columns. In a membrane contactor, CO₂ regeneration can take place below the solvent boiling point, resulting into lower consumption of energy. Various polymeric as well as ceramic membrane materials have been employed in gas liquid membrane contactors along with several solvents including amino acids, ammonia, amines etc. This review article provides detailed introduction of membrane contactors in terms of CO₂ removal. It also discusses that the main challenge that is faced by membrane contactors is membrane pore wetting caused by solvent that in turn can reduce the mass transfer coefficient. Other potential challenges such as selection of suitable solvent and membrane pair as well as fouling are also discussed in this review and are followed by potential ways to reduce them. Furthermore, both membrane gas separation and membrane contactor technologies are analysed and compared in this study on the basis of their characteristics, CO₂ separation performances and techno economical transvaluation. Consequently, this review provides an opportunity to thoroughly understand the working principle of membrane contactors along its comparison with membrane-based gas separation technology. It also provides a clear understanding of latest innovations in membrane contactor module designs as well as challenges encountered by membrane contactors along with possible solutions to overcome these challenges. Finally, semi commercial and commercial implementation of membrane contactors has been highlighted.

Cost Profile of Membranes That Use Polymers of Intrinsic Microporosity (PIMs)

Assessing the financial impact of polymers of intrinsic microporosity, otherwise known as PIMs, at the lab scale has been impeded by the absence of a holistic approach that would envelop all related financial parameters, and most importantly any indirect costs, such as laboratory accidents that have been consistently neglected and undervalued in past assessments. To quantify the cost of PIMs in relation to the risks befalling a laboratory, an innovative cost evaluation approach was designed. This approach consists of three stages. Firstly, a two-fold “window of opportunity” (WO) theory is suggested, dividing the total cost profile into two segments, followed up by a qualitative risk analysis to establish the potential cost components. The last stage builds on a total cost of ownership model, incorporating the two types of WO. The total cost of ownership (TCO) approach was selected to ascertain the costs and construct the cost profile of PIMs, according to laboratory experimental data. This model was applied to the synthesis and physicochemical characterization processes. The quantitative analysis revealed that the most influential parameters for synthesis are accidents and energy costs. This is in contrast with the physicochemical characterization process, where the most important determinant is the energy cost.

Comparison of the most likely low-emission electricity production systems in Estonia

To meet targets for reducing greenhouse gas emissions, many countries, including Estonia, must transition to low-emission electricity sources. Based on current circumstances, the most likely options in Estonia are renewables with energy storage, oil shale power plants with carbon capture and storage (CCS), or the combination of renewables and either oil shale or nuclear power plants. Here we compare these different scenarios to help determine which would be the most promising based on current information. For the comparison we performed simulations to assess how various systems meet the electricity demand in Estonia and at what cost. Based on our simulation results and literature data, combining wind turbines with thermal power plants would provide grid stability at a more affordable cost. Using nuclear power to compliment wind turbines would lead to an overall levelized cost of electricity (LCOE) in the range of 68 to 150 EUR/MWh (median of 103 EUR/MWh). Using oil shale power plants with CCS would give a cost between 91 and 163 EUR/MWh (median of 118 EUR/MWh). By comparison, using only renewables and energy storage would have an LCOE of 106 to 241 EUR/MWh (median of 153 EUR/MWh).

An Extrinsic-Pore-Containing Molecular Sieve Film: A Robust, High-Throughput Membrane Filter

MFI type zeolites with 10-membered-ring pores (ca. 0.55 nm) have the ability to separate p-xylene (ca. 0.58 nm) from its bulkier isomers. Here, we introduced non-zeolitic micropores (ca. 0.6-1.5 nm) and mesopores (ca. 2-7 nm) to a conventional microporous MFI type zeolite membrane, yielding an unprecedented hierarchical membrane structure. The uniform, embedded non-zeolitic pores decreased defect formation considerably and facilitated molecular transport, resulting in high p-xylene perm-selectivity and molar flux. Specifically, compared to a conventional, crack network-containing MFI membranes of similar thickness (ca. 1 μm), the mesoporous MFI membranes showed almost double p-xylene permeance (ca. 1.6±0.4×10^-7  mol m^-2  s^-1  Pa^-1 ) and a high p-/o-xylene separation factor (ca. 53.8±7.3 vs. 3.5±0.5 in the conventional MFI membrane) at 225 °C. The embedded non-zeolitic pores allowed for decreasing the separation performance degradation, which was apparently related to coke formation.

Effect of Water and Organic Pollutant in CO2/CH4 Separation Using Hydrophilic and Hydrophobic Composite Membranes

Membrane technology is a simple and energy-conservative separation option that is considered to be a green alternative for CO2 capture processes. However, commercially available membranes still face challenges regarding water and chemical resistance. In this study, the effect of water and organic contaminants in the feed stream on the CO2/CH4 separation performance is evaluated as a function of the hydrophilic and permselective features of the top layer of the membrane. The membranes were a commercial hydrophobic membrane with a polydimethylsiloxane (PDMS) top layer (Sulzer Chemtech) and a hydrophilic flat composite membrane with a hydrophilic [emim][ac] ionic liquid-chitosan (IL-CS) thin layer on a commercial polyethersulfone (PES) support developed in our laboratory. Both membranes were immersed in NaOH 1M solutions and washed thoroughly before characterization. The CO2 permeance was similar for both NaOH-treated membranes in the whole range of feed concentration (up to 250 GPU). The presence of water vapor and organic impurities of the feed gas largely affects the gas permeance through the hydrophobic PDMS membrane, while the behavior of the hydrophilic IL-CS/PES membranes is scarcely affected. The effects of the interaction of the contaminants in the membrane selective layer are being further evaluated.

Hollow Fiber Membrane Contactors for Post-Combustion Carbon Capture: A Review of Modeling Approaches

Hollow fiber membrane contactors (HFMCs) can effectively separate CO2 from post-combustion flue gas by providing a high contact surface area between the flue gas and a liquid solvent. Accurate models of carbon capture HFMCs are necessary to understand the underlying transport processes and optimize HFMC designs. There are various methods for modeling HFMCs in 1D, 2D, or 3D. These methods include (but are not limited to): resistance-in-series, solution-diffusion, pore flow, Happel’s free surface model, and porous media modeling. This review paper discusses the state-of-the-art methods for modeling carbon capture HFMCs in 1D, 2D, and 3D. State-of-the-art 1D, 2D, and 3D carbon capture HFMC models are then compared in depth, based on their underlying assumptions. Numerical methods are also discussed, along with modeling to scale up HFMCs from the lab scale to the commercial scale.

Techno-Economic Assessment of Different Heat Exchangers for CO2 Capture

We examined the cost implications of selecting six different types of heat exchangers as the lean/rich heat exchanger in an amine-based CO2 capture process. The difference in total capital cost between different capture plant scenarios due to the different costs of the heat exchangers used as the lean/rich heat exchanger, in each case, is in millions of Euros. The gasketed-plate heat exchanger (G-PHE) saves significant space, and it saves considerable costs. Selecting the G-PHE instead of the shell and tube heat exchangers (STHXs) will save €33 million–€39 million in total capital cost (CAPEX), depending on the type of STHX. About €43 million and €2 million in total installed costs (CAPEX) can be saved if the G-PHE is selected instead of the finned double-pipe heat exchanger (FDP-HX) or welded-plate heat exchanger, respectively. The savings in total annual cost is also in millions of Euros/year. Capture costs of €5/tCO2–€6/tCO2 can be saved by replacing conventional STHXs with the G-PHE, and over €6/tCO2 in the case of the FDP-HX. This is significant, and it indicates the importance of clearly stating the exact type and not just the broad classification of heat exchanger used as lean/rich heat exchanger. This is required for cost estimates to be as accurate as possible and allow for appropriate comparisons with other studies. Therefore, the gasketed-plate heat exchanger is recommended to save substantial costs. The CO2 capture costs of all scenarios are most sensitive to the steam cost. The plate and frame heat exchangers (PHEs) scenario’s capture cost can decline from about €77/tCO2 to €59/tCO2 or rise to €95/tCO2.

Recent Progress in the Engineering of Polymeric Membranes for CO2 Capture from Flue Gas

CO2 capture from coal- or natural gas-derived flue gas has been widely considered as the next opportunity for the large-scale deployment of gas separation membranes. Despite the tremendous progress made in the synthesis of polymeric membranes with high CO2/N2 separation performance, only a few membrane technologies were advanced to the bench-scale study or above from a highly idealized laboratory setting. Therefore, the recent progress in polymeric membranes is reviewed in the perspectives of capture system energetics, process synthesis, membrane scale-up, modular fabrication, and field tests. These engineering considerations can provide a holistic approach to better guide membrane research and accelerate the commercialization of gas separation membranes for post-combustion carbon capture.

Advanced Membranes and Learning Scale Required for Cost-Effective Post-combustion Carbon Capture

This study offers an integrated vision for advanced membrane technology for post-combustion carbon capture. To inform development of new-generation materials, a plant-level techno-economic analysis is performed to explore major membrane property targets required for cost-effective CO₂ capture. To be competitive with amine-based nth-of-a-kind (NOAK) technology or meet a more ambitious cost target for 90% CO₂ capture, advanced membranes should have a higher CO₂ permeance than 2,250 GPU and a higher CO₂/N₂ selectivity than 30 if their installed prices are higher than $50/m². To assess learning experience required for advanced technology using such high-performance membranes toward commercialization, a hybrid approach that combines learning curves with the techno-economic analysis is applied to project the cumulative installed capacity necessary for the evolution from first-of-a-kind to NOAK systems. The estimated learning scale for advanced membrane technology is more than 10 GW, depending on multiple factors. Implications for research, development, and policy are discussed.

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A forward-looking assessment is provided for advanced membrane technology

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Major material property targets are identified for advanced membranes

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This study demonstrates the evolutionary trend of advanced membrane technology

CO2 capture and storage: A way forward for sustainable environment

The quest for a sustainable environment and combating global warming, carbon capture, and storage (CCS) has become the primary resort. A complete shift from non-renewable resources to renewable resources is currently impossible due to its major share in energy generation; making CCS an imperative need of the time. This study, therefore, aims to examine the reckoning of carbon dioxide (CO₂), measurement methods, and its efficient capture and storage technologies with an ambition to combat global warming and achieve environmental sustainability. Conventionally, physical, geological and biological proxies are used to measure CO₂. The recent methods for CO₂ analyses are spectrometry, electrochemical gas sensors, and gas chromatography. Various procedures such as pre, post, and oxyfuel combustion, and use of algae, biochar, and charcoal are the promising ways for CO₂ sequestration. However, the efficient implementation of CCS lies in the application of nanotechnology that, in the future, could provide a better condition for the environment and economic outlooks. The captured carbon can be stored in the earth crust for trillions of years, but its leakage during storage can raise many issues including its emissions in the atmosphere and soil acidification. Therefore, global and collective efforts are required to explore, optimize and implement new techniques for CCS to achieve high environmental sustainability and combat the issues of global warming.

Optimal Design of a Two-Stage Membrane System for Hydrogen Separation in Refining Processes

This paper fits into the process system engineering field by addressing the optimization of a two-stage membrane system for H2 separation in refinery processes. To this end, a nonlinear mathematical programming (NLP) model is developed to simultaneously optimize the size of each membrane stage (membrane area, heat transfer area, and installed power for compressors and vacuum pumps) and operating conditions (flow rates, pressures, temperatures, and compositions) to achieve desired target levels of H2 product purity and H2 recovery at a minimum total annual cost. Optimal configuration and process design are obtained from a model which embeds different operating modes and process configurations. For instance, the following candidate ways to create the driving force across the membrane are embedded: (a) compression of both feed and/or permeate streams, or (b) vacuum application in permeate streams, or (c) a combination of (a) and (b). In addition, the potential selection of an expansion turbine to recover energy from the retentate stream (energy recovery system) is also embedded. For a H2 product purity of 0.90 and H2 recovery of 90%, a minimum total annual cost of 1.764 M$·year−1 was obtained for treating 100 kmol·h−1 with 0.18, 0.16, 0.62, and 0.04 mole fraction of H2, CO, N2, CO2, respectively. The optimal solution selected a combination of compression and vacuum to create the driving force and removed the expansion turbine. Afterwards, this optimal solution was compared in terms of costs, process-unit sizes, and operating conditions to the following two sub-optimal solutions: (i) no vacuum in permeate stream is applied, and (ii) the expansion turbine is included into the process. The comparison showed that the latter (ii) has the highest total annual cost (TAC) value, which is around 7% higher than the former (i) and 24% higher than the found optimal solution. Finally, a sensitivity analysis to investigate the influence of the desired H2 product purity and H2 recovery is presented. Opposite cost-based trade-offs between total membrane area and total electric power were observed with the variations of these two model parameters. This paper contributes a valuable decision-support tool in the process system engineering field for designing, simulating, and optimizing membrane-based systems for H2 separation in a particular industrial case; and the presented optimization results provide useful guidelines to assist in selecting the optimal configuration and operating mode.

Coal with Carbon Capture and Sequestration is not as Land Use Efficient as Solar Photovoltaic Technology for Climate Neutral Electricity Production

Avoiding climate destabilization caused by greenhouse gas (GHG) emissions, requires climate-neutral electricity sources. It has been proposed that the GHG emissions from coal-fired power plants can be offset by carbon capture and sequestration or bio-sequestration. However, solar photovoltaic (PV) technology has recently declined so far in costs it now offers both technical and economic potential to offset all of coal-fired electricity use. PV only emits GHGs during fabrication and not during use. To determine which technical solution to climate-neutral electricity generation should be preferred, this study aggregates and synthesizes life cycle analysis studies for exergy, GHG emissions and land transformation for climate-neutral electricity. The results show that because of lower exergy efficiencies coal plants emit 13-18 times more GHG and transform 5-13 times more land than PV. Optimal bio-sequestration of coal-fired GHG requires 62% of U.S. arable land or 89% of all U.S land with average forest cover. Carbon capture and storage and enhanced oil recovery can improve coal performance, but for all cases the results clearly show that PV is a far more effective use of land. Overall, for the first time this study found climate-neutral photovoltaic farms are a preferred solution to climate-neutral coal fired electricity generation.

Systems Analysis of Physical Absorption of CO2 in Ionic Liquids for Pre-Combustion Carbon Capture

This study develops an integrated technical and economic modeling framework to investigate the feasibility of ionic liquids (ILs) for precombustion carbon capture. The IL 1-hexyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide is modeled as a potential physical solvent for CO₂ capture at integrated gasification combined cycle (IGCC) power plants. The analysis reveals that the energy penalty of the IL-based capture system comes mainly from the process and product streams compression and solvent pumping, while the major capital cost components are the compressors and absorbers. On the basis of the plant-level analysis, the cost of CO₂ avoided by the IL-based capture and storage system is estimated to be $63 per tonne of CO₂. Technical and economic comparisons between IL- and Selexol-based capture systems at the plant level show that an IL-based system could be a feasible option for CO₂ capture. Improving the CO₂ solubility of ILs can simplify the capture process configuration and lower the process energy and cost penalties to further enhance the viability of this technology.

Vanadium As a Potential Membrane Material for Carbon Capture: Effects of Minor Flue Gas Species

Vanadium and its surface oxides were studied as a potential nitrogen-selective membrane material for indirect carbon capture from coal or natural gas power plants. The effects of minor flue gas components (SO₂, NO, NO₂, H₂O, and O₂) on vanadium at 500-600 °C were investigated by thermochemical exposure in combination with X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), and in situ X-ray diffraction (XRD). The results showed that SO₂, NO, and NO₂ are unlikely to have adsorbed on the surface vanadium oxides at 600 °C after exposure for up to 10 h, although NO and NO₂ may have exhibited oxidizing effects (e.g., exposure to 250 ppmv NO/N₂ resulted in an 2.4 times increase in surface V₂O₅ compared to exposure to just N₂). We hypothesize that decomposition of surface vanadium oxides and diffusion of surface oxygen into the metal bulk are both important mechanisms affecting the composition and morphology of the vanadium membrane. The results and hypothesis suggest that the carbon capture performance of the vanadium membrane can potentially be strengthened by material and process improvements such as alloying, operating temperature reduction, and flue gas treatment.

Comparison of CO2 Capture Approaches for Fossil-Based Power Generation: Review and Meta-Study

This work is a meta-study of CO2 capture processes for coal and natural gas power generation, including technologies such as post-combustion solvent-based carbon capture, the integrated gasification combined cycle process, oxyfuel combustion, membrane-based carbon capture processes, and solid oxide fuel cells. A literature survey of recent techno-economic studies was conducted, compiling relevant data on costs, efficiencies, and other performance metrics. The data were then converted in a consistent fashion to a common standard (such as a consistent net power output, country of construction, currency, base year of operation, and captured CO2 pressure) such that a meaningful and direct comparison of technologies can be made. The processes were compared against a standard status quo power plant without carbon capture to compute metrics such as cost of CO2 emissions avoided to identify the most promising designs and technologies to use for CO2 emissions abatement.