The Carbon Capture Simulation Initiative (CCSI) is a partnership among national laboratories, industry and academic institutions that is developing and deploying state-of-the-art computational modeling and simulation tools to accelerate the commercialization of carbon capture technologies from discovery to development, demonstration, and ultimately the widespread deployment to hundreds of power plants. The CCSI Toolset will provide end users in industry with a comprehensive, integrated suite of scientifically validated models, with uncertainty quantification (UQ), optimization, risk analysis and decision making capabilities. The CCSI Toolset incorporates commercial and open-source software currently in use by industry and is also developing new software tools as necessary to fill technology gaps identified during execution of the project. Ultimately, the CCSI Toolset will (1) enable promising concepts to be more quickly identified through rapid computational screening of devices and processes; (2) reduce the time to design and troubleshoot new devices and processes; (3) quantify the technical risk in taking technology from laboratory-scale to commercial-scale; and (4) stabilize deployment costs more quickly by replacing some of the physical operational tests with virtual power plant simulations. CCSI is led by the National Energy Technology Laboratory (NETL) and leverages the Department of Energy (DOE) national laboratories’ core strengths in modeling …

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The objective of this Stage Gate IV project was to test and substantiate the viability of an erosion‐resistant nanocoating for application on compressor airfoils for gas turbines in both industrial power generation and commercial aviation applications. To effectively complete this project, the National Energy Technology Laboratory’s Office of Research & Development teamed with MDS Coating Technologies Inc. (MCT), Delta Air Lines ‐ Technical Operations Division (Delta Tech Ops), and Calpine Corporation. The coating targeted for this application was MCT’s Next Generation Coating, version 4 (NGC‐v4 ‐ with the new registered trademark name of BlackGold®). The coating is an erosion and corrosion resistant composite nanostructured coating. This coating is comprised of a proprietary ceramic‐metallic nano‐composite construction which provides enhanced erosion resistance and also retains the aerodynamic geometry of the airfoils. The objective of the commercial aviation portion of the project was to substantiate the coating properties to allow certification from the FAA to apply an erosion‐resistant coating in a commercial aviation engine. The goal of the series of tests was to demonstrate that the durability of the airfoils is not affected negatively with the application of the NGC v4 coating. Tests included erosion, corrosion, vibration and fatigue. The results of the …

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This report is the third in a series of reports sponsored by the U.S. Department of Energy Geothermal Technologies Program in which a range of water-related issues surrounding geothermal power production are evaluated. The first report made an initial attempt at quantifying the life cycle fresh water requirements of geothermal power-generating systems and explored operational and environmental concerns related to the geochemical composition of geothermal fluids. The initial analysis of life cycle fresh water consumption of geothermal power-generating systems identified that operational water requirements consumed the vast majority of water across the life cycle. However, it relied upon limited operational water consumption data and did not account for belowground operational losses for enhanced geothermal systems (EGSs). A second report presented an initial assessment of fresh water demand for future growth in utility-scale geothermal power generation. The current analysis builds upon this work to improve life cycle fresh water consumption estimates and incorporates regional water availability into the resource assessment to improve the identification of areas where future growth in geothermal electricity generation may encounter water challenges. This report is divided into nine chapters. Chapter 1 gives the background of the project and its purpose, which is to assess the water …

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The objective of this project was to demonstrate the potential of a new process technology to reduce the energy consumption and CO{sub 2} emission from the production of titanium dioxide (TiO{sub 2}) pigment. TiO{sub 2} is one of the most commonly used minerals in the chemical manufacturing industry. It has been commercially processed as a pigment since the early 1900's, and has a wide variety of domestic and industrial applications. TiO{sub 2} pigment is currently produced primarily by the use of the so called �chloride process�. A key step of the chloride process relies on high temperature carbo-chlorination of TiO{sub 2} bearing raw materials, hence producing large quantities of CO{sub 2}. The new method uses a chemical/metallurgical sequential extraction methodology to produce pigment grade TiO{sub 2} from high-TiO{sub 2} slag. The specific project objectives were to 1) study and prove the scientific validity of the concept, 2) understand the primary chemical reactions and the efficiency of sequential extraction schemes, 3) determine the properties of TiO{sub 2} produced using the technology, and 4) model the energy consumptions and environmental benefits of the technology. These objectives were successfully met and a new process for producing commercial quality TiO{sub 2} pigment was developed …

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The main focus of this American Recovery and Reinvestment Act of 2009 (ARRA) funded project was to design an energy efficient carbon capture and storage (CCS) process using the Recipient�s membrane system for H{sub 2} separation and CO{sub 2} capture. In the ARRA-funded project, the Recipient accelerated development and scale-up of ongoing hydrogen membrane technology research and development (R&D). Specifically, this project focused on accelerating the current R&D work scope of the base program-funded project, involving lab scale tests, detail design of a 250 lb/day H{sub 2} process development unit (PDU), and scale-up of membrane tube and coating manufacturing. This project scope included the site selection and a Front End Engineering Design (FEED) study of a nominally 4 to 10 ton-per-day (TPD) Pre-Commercial Module (PCM) hydrogen separation membrane system. Process models and techno-economic analysis were updated to include studies on integration of this technology into an Integrated Gasification Combined Cycle (IGCC) power generation system with CCS.

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Project OASIS (Operation of Advanced Structures, Interfaces and Sub-components for MEAs) was a 12 month project that ran from 1st September 2008 to 31st August 2009, and was managed by the Department of Energy Office of Science, Chicago Office, as Award No DE-FG02-08ER64658, with Johnson Matthey Fuel Cells Inc. as the sole contractor. The project was completed on schedule, with technical successes (details below) and payment of the full grant award made by DOE. The aim of the project was the development of membrane electrode assemblies (MEAs) for H2/air polymer electrolyte membrane (PEM) fuel cells that would give higher performance under hot/dry and dry operating conditions, ideally with no loss of performance under wet conditions. Reducing or eliminating the need for humidifying the incoming gases will allow significant system cost and size reduction for many fuel cell applications including automotive, stationary and back-up power, and portable systems. Portable systems are also of particular interest in military markets. In previous work Johnson Matthey Fuel Cells had developed very stable, corrosion-resistant catalysts suitable for resisting degradation by carbon corrosion in particular. These materials were applied within the OASIS project as they are considered necessary for systems such as automotive where multiple start-stop …

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