TDA RESEARCH, INC. — Department of Energy SBIR Phase II: 15b

Description

Gasification technologies convert coal and biomass into synthesis gas feed streams that can either be used as a fuel for highly efficient power generation cycles or converted into value added chemicals and transportation fuels. However, coal derived synthesis gas contains a myriad of contaminants that may be egulated in power plant emissions and act as poisons for the catalysts used in downstream chemical manufacturing processes. TDA Research, Inc. (TDA) is developing a low cost, high capacity, sorbent that can remove ammonia and hydrogen cyanide (NH3 and HCN, the acid rain precursors) and the trace metal contaminants (such as mercury, arsenic and selenium) from the synthesis gas in a single process step. Unlike the commercially available gas cleanup technologies, our multi contaminant control system operates at 240oC (464oF), above the dew point of the synthesis gas; operating above the dew point improves process efficiency and reduces capital costs. During Phase II we continued to improve the performance of our sorbent. We scale dup its production using commercial manufacturing techniques, and completed a 500 cycle test to demonstrate its life and activity in a multi bed laboratory reactor. In a prototype unit, we demonstrated the viability of the technology using actual coal derived synthesis gas at the National Carbon Capture Center. We also completed a detailed engineering analysis to fully quantify the benefits of the new technology. In the Phase IIE effort, we will develop a fully automated multi contaminant removal system that is capable of treating 10 SCFM of synthesis gas. We will carry out extended tests using coal derived synthesis gas to fully the demonstrate the concept. We will carry out detailed process simulations using AspenPlusTM to accurately estimate the economic value of the new technology integrated with different gasifiers, treating synthesis gas generated from different coal (and potentially other) feedstocks. We will complete the design of a world scale system with accurate cost estimates from vendors. The use of coal derived synthesis gas in power generation is an emerging technology with significant commercial potential, because gasification based power cycles operate with much higher efficiency than conventional pulverized coal combustion plants. Key Words: Warm gas cleanup; ammonia, mercury, arsenic removal; gasification technologies. With 250 billion tons of known reserves, coal is one of the most prominent U.S. energy sources, and it can be used in efficient electrical power generation cycles or in the production of synthetic fuels. TDA’s technology will provide an enabling technology that will advance the widespread implementation and environmentally friendly use of coal.