Illinois Sustainable Technology Center • Prairie Research Institute
Read the full story from WCIA. See also coverage from WBBM and read more about the ISTC-led project.
The University of Illinois’ Prairie Research Institute, broke ground on its carbon capture pilot project at the City Water, Light and Power (CWLP) Dallman Unit 4 plant Thursday. The project is meant to reduce and eventually eliminate carbon emissions.
Visitors from the U.S. Department of Energy National Energy Technology Laboratory (DOE-NETL) recently toured multiple carbon capture projects led by the Illinois Sustainable Technology Center (ISTC).
Because the unique geology of Illinois provides extensive potential to store carbon dioxide deep underground, the state is also an ideal location to develop, demonstrate, and deploy technologies to capture CO2 from point sources, remove CO2 from the ambient air, and beneficially use CO2. ISTC scientists and engineers lead a number of carbon capture, removal, and use projects backed by funding from the Department of Energy.
The tour included carbon capture projects at Abbott Power Plant at the University of Illinois Urbana-Champaign; City Water, Light & Power in Springfield, Prairie State Generating Company in Marissa, Illinois; and the Ste. Genevieve Cement Plant in Missouri.
The University’s Abbott Power Plant , a cogeneration facility that simultaneously produces both steam and electricity to meet 70-75% of the Urbana campus’s energy needs, is a partner on two ISTC-led carbon capture projects.
ISTC led a project, supported by $3.4 million from DOE-NETL, to evaluate an innovative biphasic solvent system for its efficiency and effectiveness in absorbing CO₂ from flue gas at Abbott. The system was designed based on the testing results at the laboratory scale under a previous DOE cooperative agreement. Read more about the biphasic solvent system.
A second project is based on a mixed-salt carbon capture technology developed by SRI International. This technology is being tested at engineering scale at Abbott in a 0.5 megawatt electric (MWe) equivalent pilot campaign. This project is supported by a grant of more than $18 million from DOE-NETL. Read more about the mixed-salt capture technology.
ISTC leads the large-scale pilot testing of a Linde-BASF CO2 solvent-based carbon capture technology at City Water, Light & Power (CWLP) in Springfield, Illinois. When the 10-megawatt capture system is built and begins to process 5 percent of the Dallman Unit 4 flue gas, it will capture more than 90 percent of those CO2 emissions. DOE has provided $47 million for this build-operate project, and the State of Illinois has pledged an additional $20 million. Read more about the large pilot project at CWLP.
A second project led by ISTC and backed by $25 million from DOE aims to design a next-generation power plant at CWLP that both reduces emissions and captures and uses carbon dioxide. The design combines a 270-megawatt ultra-supercritical coal boiler, an 87-megawatt natural gas combustion turbine generator, a 50-megawatt energy storage subsystem, and a post-combustion carbon capture subsystem. Read more about the next-generation power plant project.
ISTC is investigating the use of CO2 captured from CWLP, as well as nutrients from wastewater treatment plants to grow algae. The cultivated high-protein Spirulina can be used in animal feeds. This engineering-scale algae project is supported by $2.5 million from DOE. Read more about the algae project.
ISTC leads a front-end engineering design (FEED) study to retrofit the Prairie State Generating Company (PSGC) in Marissa, Illinois, with a solvent-based post-combustion carbon capture technology from Mitsubishi Heavy Industries. At 816 megawatts, this is the largest carbon capture FEED study in the world, with a system projected to be capable of capturing 8.5 million tonnes of CO2 each year. Read more about the FEED study at Prairie State Generating Company.
Cement is a ubiquitous construction material, and its production produces tonnes of carbon dioxide each year. While scientists are working on alternative cements and lower-carbon production processes, it is likely that capturing and either using or storing emissions from cement production will be necessary to meet carbon reduction targets.
ISTC leads a front-end engineering and design (FEED) study for a commercial-scale carbon capture retrofit of Holcim’s Ste. Genevieve Cement Plant in Bloomsdale, Missouri. The project focuses on Air Liquide’s CrycocapTM FG system for carbon capture and is backed by $4 million from DOE-NETL. Read more about the Ste. Genevieve carbon capture project.
Projects to remove carbon dioxide from ambient air, called direct air capture (DAC), were not included in the recent tour but are a growing part of ISTC’s carbon management portfolio.
ISTC leads a project, backed by a grant of nearly $2.5 million from DOE-NETL, to develop preliminary designs and determine feasibility for the first commercial-scale direct air capture and storage system (DAC+S) for CO2 removal in the United States. This 18-month project will explore the possibility of pulling 100,000 tonnes of CO2 from the air annually, using technology from the Swiss company Climeworks, which has built and operated several DAC plants in various climates across Europe. The ISTC-led team will test the large-scale DAC systems at three sites across the U.S. in order to assess how different climate conditions impact the process. Read more about the DAC+S project.
ISTC and Climeworks also are collaborating on a $2.5 million FEED study of a DAC system to capture CO2 for underground storage. The California host site, a geothermal plant, will provide thermal energy to drive the DAC process; the site also is close to a proposed geological storage facility in the Joaquin Basin.
ISTC also leads a FEED study of direct air capture technology developed by CarbonCapture Inc. at U. S. Steel’s Gary Works Plant in Gary, Indiana. This project incorporates use of the captured carbon dioxide at a nearby Ozinga ready mix concrete plant. Injecting the CO2 into the concrete as it is being mixed causes the CO2 to mineralize, locking it in the concrete and preventing it from returning to the atmosphere. By using the U. S. Steel plant’s waste heat, energy needs can be reduced. Read more about the carbon capture and use FEED study at U. S. Steel’s Gary Works Plant.
Finally, ISTC is a partner on a project that is exploring the benefits of constructing DAC technology at Constellation Energy’s Byron nuclear energy plant in Northern Illinois. Although nuclear plants do not produce carbon emissions, the plant can provide energy to power the DAC system, which could capture 250,000 tons of CO2 each year.
Read more about sustainable energy research and development at the Prairie Research Institute.
Illinois Sustainable Technology Center (ISTC) researchers have given the thumbs up to an innovative biphasic solvent system for its efficiency and effectiveness in absorbing CO₂ from flue gas in a coal-fired power plant at the University of Illinois (U of I).
With $3.4 million from the U.S. Department of Energy (DOE) National Energy Technology Laboratory, an ISTC team sought to validate the various advantages of a biphasic CO₂ absorption process (BiCAP) at a 40-kilowatt electric small pilot scale at the Abbott Power Plant on the U of I campus. The system was designed based on the testing results at the laboratory scale under a previous DOE cooperative agreement.
Previous laboratory testing has proved the biphasic solvent-based process concept and has shown that the technique can achieve greater than 90 percent capture efficiency and greater than 95 percent CO₂ purity and has the potential to significantly increase energy efficiency and reduce CO₂ capture cost.
From the recent field testing, the team verified that their technology could achieve 95 percent efficiency in CO₂ capture, compared with 90 percent in conventional methods, with a 40 percent higher energy efficiency. The cost advantages have not yet been determined, but previous laboratory testing showed a 26 percent cost reduction. The system has also been shown to run continuously for two weeks, verifying that it can operate under Midwest winter weather conditions.
“The conventional CO₂ capture process has several disadvantages, and our goal was to reduce the carbon footprint and costs and increase the energy efficiency,” said Yongqi Lu, principal investigator. “These energy-efficiency advantages of the BiCAP system, coupled with reduced equipment sizes when scaled up for commercial systems, will lead to reductions in both capital and operating expenses.”
The BiCAP method uses biphasic solvent blends that can form and develop dual-liquid phases during CO₂ absorption. The solvents, which were tested and selected in previous DOE-funded studies, are highly resistant to degrading from either high temperatures or oxidative atmospheres. Also, less solvent is required for this process.
Although the focus of the study was on CO₂ capture from flue gas at coal-fired power plants, the BiCAP technology can be used in natural gas combined cycle (NGCC) plants as well, incorporating flue gas from natural gas, biomass, plastics, and other renewable materials.
“The exciting feature of this capture technology is its robust nature and ability to be used on a variety of flue gas sources. We are now ready for commercial partners to assist in moving this technology to the marketplace,” said Kevin OBrien, co-principal investigator for the project and director of ISTC.
Preliminary tests with synthetic NGCC flue gas made of air and bottled CO2 gas have been performed on the small pilot unit recently. Results revealed that a 95 percent CO2 removal rate could be achieved, and the energy use only slightly increased compared with that for the coal flue gas that contains more concentrated CO2.
The concept of biphasic solvents was developed as part of a dissertation research project in 2013–2015. From 2015 through 2018, screening of biphasic solvents and studies of proof of the BiCAP process concept were conducted at the laboratory scale with funding from DOE. After that, the small pilot system was designed, constructed, and tested at the Abbott Power Plant with continued DOE support.
The main research team for this project was transferred from the Illinois State Geological Survey (ISGS) to ISTC in January 2022. Now that the team has collected the data, the next steps are to complete a techno-economic analysis, then scale-up the technology for commercial use.
Media contact: Yongqi Lu, 217-244-4985, yongqilu@illinois.edu or
news@prairie.illinois.edu
This story first appeared on the Prairie Research Institute News Blog. Read the original story.
Several ISTC researchers recently had abstracts accepted for the 16th Greenhouse Gas Control Technologies Conference (GHGT16), to be held October 23-27, 2022 in Lyon, France.
GHGT is the principal international conference for greenhouse gas mitigation technologies and focuses on carbon capture, utilization, and storage.
The abstracts accepted for the conference are:
Lance Schideman’s research on using carbon dioxide from power plants to cultivate algae for animal feed is featured in the Popular Science article “The cost of algae-based biofuel is still too high.”
On Dec. 9, U.S. Secretary of Energy Jennifer M. Granholm toured several U of I sustainable energy projects, including PRI’s carbon capture efforts at Abbott Power Plant. During the visit she also heard about PRI’s extensive work in carbon sequestration.
Read more about PRI’s carbon management and sustainable energy research.
Read more about Secretary Granholm’s visit to U of I from The News-Gazette and Illinois Newsroom.
The U.S. Department of Energy’s National Energy Technology Laboratory (DOE-NETL) selected the University of Illinois for $4 million in funding, in addition to cost share contributions by LafargeHolcim and Air Liquide, for research and development to support a front-end engineering design (FEED) study of a carbon capture retrofit at an industrial facility in Missouri.
A three-year, $2.5 million Illinois Sustainable Technology Center (ISTC) engineering-scale project will be one of the first and largest to combine carbon dioxide (CO2) from a coal-fired power plant with nutrients from wastewater treatment plants to cultivate algae for animal feeds. The project will demonstrate that producing algae for commodity animal products can be cost-effective and has added environmental benefits.
Algae has been used for decades in the niche markets of health and beauty. A more recent focus is its ability to use CO2 from coal-fired power plants to make biofuels and protein-rich food products.
Algae is fast-growing compared with traditional terrestrial feed crops, so it’s an attractive alternative for use in taking up CO2 from power plants because it requires less land, according to ISTC principal investigator Lance Schideman. Researchers will use the algae species Spirulina because it is already FDA approved for use as a food ingredient and has a high protein content, which commands higher prices.
The algae cultivation system will be integrated with the City Water, Light and Power plant in Springfield, Illinois. Schideman is collaborating with University of Illinois researchers Joshua McCann and Carl Parsons, who will conduct the animal feed studies. Global Algae Innovations will provide the algae biomass production system to be demonstrated at field scale for this project. The project is co-funded by the U.S. Department of Energy National Energy Technology Laboratory.
In the past, ISTC scientists have researched wastewater algae systems that are now used at 10 full-scale operating wastewater plants. They’ve also been a leader in recycling the byproducts of hydrothermal biofuel production to enhance algal biomass productivity. Global Algae Innovations is a leading designer and equipment supplier in the algae industry that has developed and demonstrated cost-effective, large-scale algae production systems.
“We’re putting all the pieces together in a coordinated fashion and lowering the net costs of growing algae using industrial and municipal by-products as inputs to improve the economic environmental sustainability of algal carbon capture,” Schideman said.
This approach reduces pollution and replaces the costly CO2 and nutrient inputs used in most algae cultivation systems. In the current commercial technology, managers buy liquid CO2 and various commercial fertilizers for the nutrient supply.
The wastewater, which is full of organic nutrients that support algae growth, will come from a local wastewater treatment plant.
“Using wastewater is a cost savings in the production process and it helps to solve problems that wastewater treatment plants are experiencing in trying to minimize nutrient discharges in the environment,” Schideman said. “In Illinois, the treatment plants are under increasing scrutiny, and regulations that are now voluntary are expected to become more stringent and potentially mandatory within the next decade.”
Ultimately, the system will produce feed especially for cattle and chickens. The product will be dry, which helps reduce spoilage, and will have a high nutritional value compared with some other feeds.
The typical price range for most bulk animal feed ingredients is $150–350 per ton, and certain high-value products can have a market value of $1,000–$2,000 per ton. Algae has the potential to command prices near the top of the range since some species contain highly nutritional components such as antioxidants and poly-unsaturated fatty acids. However, algal animal feeds are not yet established in the market, and the value of these products must be demonstrated through research studies like this one.
Schideman notes that the size of the animal feeds market is quite large and is a good match with the amount of CO2 produced by power plants around the country. Thus, using CO2 from flue gas in algae production has the potential to significantly reduce greenhouse gasses.
Media contact: Lance Schideman, 217-390-7070, schidema@illinois.edu
news@prairie.illinois.edu
Carbon emissions continue to rise, ratcheting up temperatures and driving increasingly extreme weather events worldwide. Therefore, carbon capture and management will be a crucial step in curbing climate change.
There are two main categories of carbon emissions: point-source and nonpoint-source. Point-source emissions come from a single source such as a power plant or a factory. Nonpoint-source emissions are harder to pinpoint and to address because they cover a widespread area and can come from a variety of sources like automobiles, airplanes, boats, and more.
“In order to offer a more robust solution to carbon management, you have to be able to address both point-source emissions and nonpoint-source emissions,” said Kevin OBrien, director of the Illinois Sustainable Technology Center (ISTC).
The U.S. Department of Energy National Energy Technology Laboratory (DOE-NETL) has partnered with ISTC in a nearly $2.5 million project to develop preliminary designs and determine feasibility for the first commercial-scale direct air capture and storage system (DAC+S) for CO2 removal in the United States.
This 18-month project will explore the possibility of pulling 100,000 tonnes of CO2 from the air annually. Project principal investigator OBrien believes this amount will help offset steep upfront costs and make the service profitable, at least at a commercial scale.
“The potential impact this could have would be immense, because now you can address unavoidable nonpoint sources by pulling CO2 out of the air, hopefully in any type of climate anywhere around the world,” said OBrien.
The project will use DAC technology provided by the Swiss company Climeworks. Climeworks has built and operated several DAC plants in various climates across Europe, among them the world’s first industrial-scale DAC plant in Hinwil, Switzerland, and the world’s largest DAC+S plant, Orca, in Hellisheidi, Iceland.
Widespread deployment of DAC systems in the U.S. must account for wide variations in regional climates. Temperature and relative humidity can impact the efficiency of CO2 removal technologies.
The ISTC-led team will address climate efficiency challenges by testing the large-scale DAC systems and storing the captured CO2 at three test sites across the U.S., examining the effects of different climate conditions on CO2 storage.
In addition to Climeworks, major partners in the project consortium include Kiewit Power Engineers, Lawrence Livermore National Laboratory, Gulf Coast Sequestration, North Shore Energy, Sunpower, Ormat, and Sentinel Peak.
For more information, read the entire DOE announcement.
Media contacts: Kevin OBrien, kcobrien@illinois.edu; news@prairie.illinois.edu
From 2018 to 2020, ISTC submitted over 200 proposals for technology R&D projects, winning more than 60 percent of those projects and bringing in more than $84 million in external funding. Major partners include the U.S. Department of Energy (DOE), U.S. Environmental Protection Agency (EPA), and the state of Illinois.
“We have a very strong technical team with extensive industrial experience,” explained Kevin OBrien, director of ISTC and the Illinois State Water Survey (ISWS). “The key thing with experience is everyone is bringing their own knowledge and expertise to the table, whether it’s knowing permitting and regulatory procedures, understanding how to scale up and construct these large systems, or understanding techno-economics and lifecycle assessments.”
ISTC’s planning process is comprehensive and organized. The journey from lab to commercial scale involves a team of engineers, accountants, and project managers who focus on correctly handling every detail.
“We realized long ago that executing a successful interdisciplinary research endeavor at a commercial scale is a meticulous journey that requires significant experience, technical expertise, and trial and error,” OBrien said. “We’re unique in that we can check all of those boxes at a very high level and offer new technologies and opportunities to our partner host sites.”
One of those partners is City Water, Light, and Power (CWLP) in Springfield, Illinois. Over the past 15 years, CWLP has partnered with ISTC on several projects, including work on emissions, CO2, and wastewater. “We’ve really run the environmental gamut with ISTC,” said PJ Becker, environmental health and safety manager at CWLP. “ISTC has been a responsive and professional partner and we’ve been able to benefit immensely from the technology.”
ISTC environmental engineer Stephanie Brownstein is the lead for the large pilot test of the Linde-BASF carbon capture technology at CWLP. “We’re a diverse group with people on our team who are experienced with fieldwork and process work to be a liaison between partners,” she said. “Also, we don’t own the technology, which helps us work to be a broader advocate for everyone. We’re fighting for the success of the project as a whole, not just a single entity.”
Prairie State Generating Company (PSGC) in Marissa, Illinois, is another of ISTC’s project partners. ISTC, ISWS, the Illinois State Geological Survey (ISGS), and partners Kiewit Engineering Group, Mitsubishi Heavy Industries America, and Sargent & Lundy will design a system to capture more than 90 percent of carbon emissions at the facility and incorporate additional carbon offset strategies to achieve net-zero CO2 emissions.
The FEED study is made possible through a $15 million grant from the DOE Office of Fossil Energy, which is administered by the National Energy Technology Laboratory. PSGC contributed $3.75 million to the project.
“We envision ourselves at the forefront of the carbon capture industry and we’re currently working toward building the largest commercial carbon capture system in the world,” said Jason Dietsch, project manager for the front-end engineering design (feed) study at PSGC.”
“That vision is what pushes us to meet and exceed every milestone we set with DOE. We are part of a very broad team with very different backgrounds that complement each other, but I think what makes our team at ISTC uniquely successful is that we understand that we succeed as a team and we fail as a team,” Dietsch said.
With multiple major projects in progress or about to launch, OBrien
is optimistic about what lies ahead.
“For someone like me who started back in the lab, to see this come together is huge,” he said. “We aren’t just working at lab scale anymore, we are working at commercial scale, and it’s an exciting time to have this opportunity for ideas and concepts for carbon reduction that we have been working on for a long time to be deployed on a big stage.”