Instantaneous Capture and Mineralization of Flue Gas Carbon Dioxide: Pilot Scale Study

Multiple CO2 capture and storage (CCS) processes are required to address anthropogenic CO2 problems. However, a method which can directly capture and mineralize CO2 at a point source, under actual field conditions, has advantages and could help offset the cost associated with the conventional CCS technologies. The mineral carbonation (MC), a process of converting CO2 into stable minerals (mineralization), has been studied extensively to store CO2. However, most of the MC studies have been largely investigated at laboratory scale. Objectives of this research were to develop a pilot scale AMC (accelerated mineral carbonation) process and test the effects of flue gas moisture content on carbonation of fly ash particles. A pilot scale AMC process consisting of a moisture reducing drum (MRD), a heater/humidifier, and a fluidized-bed reactor (FBR) was developed and tested by reacting flue gas with fly ash particles at one of the largest coal-fired power plants (2120 MW) in the USA. The experiments were conducted over a period of 2 hr at ~ 300 SCFM flow-rates, at a controlled pressure (115.1 kPa), and under different flue gas moisture contents (2-16%). The flue gas CO2 and SO2 concentrations were monitored before and during the experiments by an industrial grade gas analyzer. Fly ash samples were collected from the reactor sample port from 0-120 minutes and analyzed for total inorganic carbon (C), sulfur (S), and mercury (Hg). From C, S, and Hg concentrations, %calcium carbonate (CaCO3), %sulfate (SO42-), and %mercury carbonate (HgCO3) were calculated, respectively. Results suggested significant mineralization of flue gas CO2, SO2, and Hg within 10-15 minutes of reaction. Among different moisture conditions, ~16% showed highest conversion of flue gas CO2 and SO2 to %CaCO3 and %SO42- in fly ash samples. For example, an increase of almost 4% in CaCO3 content of fly ash was observed. Overall, the AMC process is cost-effective with minimum carbon footprint and can be retrofitted to coal fired power plants (existing and/or new) as a post-combustion unit to minimize flue gas CO2, SO2, and Hg emissions into the atmosphere. Used in conjunction with capture and geologic sequestration, the AMC process has the potential to reduce overall cost associated with CO2 separation/compression/transportation/pore space/brine water treatment. It could also help protect sensitive amines and carbon filters used in flue gas CO2 capture and separation process and extend their life