Upload
others
View
5
Download
0
Embed Size (px)
Citation preview
Extremely Durable Concrete using Methane Decarbonization Nanofiber
Co-products with Hydrogen (EERE - Pipeline H2)
Modular Processing of Flare Gas for Carbon Nanoproducts (NETL - Flare
Gas)
Alan W. Weimer, PI, University of Colorado – Boulder (CU)
Mija H. Hubler, co-PI, University of Colorado – Boulder (CU)
Team Members: Forge Nano (FN), National Ready Mixed Concrete Association (NRMCA)
We are producing H2 and a beneficial carbon nanofiber concrete additive
from natural gas by chemical vapor deposition using a low-cost sacrificial
and compatible catalyst support
EERE: $1.25 M (36)
NETL: $3.75 M (41)
Project VisionTotal Project Cost (mo)
The Concept and the Project Objectives
1
The Team
2
EERE (Pipeline): In-situ Ambient Pressure ALD/CCVD Reactor Design
3
Pipeline Gas (EERE)
Key Process Parameters
Catalyst ALD fabrication In-situ
Catalyst Support Fumed Silica
Catalyst MetalMonometallic (e.g, Fe, Ni,
or Co)
Pressure Range Ambient
Temperature Range 600 – 850°C
Scale-upPipeline centralized
process
CNF applicationHigh-performance
concrete
NETL (Flare Gas): Ex-situ ALD Pressurized CCVD Reactor Design
4
Flare Gas (NETL)
Key Process Parameters
Catalyst ALD
fabrication Ex-situ
Catalyst Support Silica fume
Catalyst MetalBimetallic (e.g, Fe/Co,
Ni/Co, Fe/Ni etc…)
Pressure Range 400 – 500 psig
Temperature Range 600 – 850°C
Scale-up Modular process
Carbon Nanoproduct
Application
Ultra high-
performance concrete
EERE: Mix design and mechanical tests for HPC
5
Premixing Ultrasound
CNF addition Toughness (N-mm)Toughness
Increment (%)
No CNFs (general sand) 321 0
Ultra 0.1 cwt% of CNFs 411 +28
Ultra 0.25 cwt% of CNFs 374 +17
CNFs successfully dispersed by two stage process:
1) premixing with HRWR to change surface properties
2) Ultrasound dispersion to break Van der Waals forces
Reproduce HPC Mix design (wt.%) with Expected Performance
w/c Cement Water Sand SF HRWRCoarse
aggregate
28-day comp.
strength (psi)
0.32 19.92 6.34 27.66 1.92 0.46 43.69 9732
Ensure Minor Change in Setting time of HPC when adding CNFs
70.0
75.0
80.0
85.0
90.0
95.0
0 200 400 600 800 1000 1200 1400 1600 1800
Te
mp
era
ture
, F
Time, min.
no CNFs
ultrasonic dispersed CNFs
HPC with commercial CNF toughness testing
NETL: Mix design and mechanical tests for UPHC
6
Develop Optimized UHPC mix design
Mix w/c Cement Water Sand SF HRWRGround
quartz
1 0.22 31.62 6.97 44.28 7.89 1.33 7.89
2 0.23 30.05 6.91 51.92 9.75 1.37 0.00
3 0.22 38.68 8.53 32.54 9.66 0.94 9.66
4 0.21 34.45 7.43 34.93 6.90 1.30 14.99
5 0.18 35.84 6.45 49.51 6.64 1.55 0.00
1 2 3 4 5
17103 15412 18795 15767 18007
Averaged compressive strength of samples after 28 days curing (psi)
1 2 3 4 5
4.25 3.25 3.5 3.875 4.75
Slump test results (in)
UHPC mix design (wt.%)
Optimized for
medium slump.
Achieved required UHPC
compressive strength.
Dispersion method Peak Load (N)Peak Load
Increment (%)
NoCNFs (general sand) 6440 0
Dumpin 6094 -5
Ultra 6129 -5
Premix+Ultra 6815 +6
Fine sand only 6427 0
Fine Sand+CNFs+Ultra 6882 +7
Fine Sand+CNFs+Premix+Ultra 6936 +8
Mix design 5 with 0.1 cwt% of commercial CNFs
Flexure Test
Optimize Dispersion for Improved Flexure Strength of UHPC with Commercial CNFs
Dispersion is critical for improved
mechanical performance.
EERE Results: Preliminary Technoeconomic Analysis
7
CVD
Reactor with
Integrated
Furnace
Heat
Exchanger
Sacrificial
CatalystCNF coated
Silica Fume
770k mt/yr
Pressure
Swing
Adsorbers
Furnace
Exhaust
Hydrogen
Product
43k mt/yr
Natural Gas
Feed
12 BSCF/yr
ParametersHydrogen price: $2/kg
NG cost: $3/KSCF
IRR: 10%
Lifetime: 15 years
Estimated TDC: $2B-4B
Cost of Capital: 8.5%
ResultsCNF coated silica, price range:
$2 - $4 per kg
Pure CNF, price range:
$10 - $20 per kg
Pure CNF, current technology:
$300 per kg (bulk)
Compressor
NETL Results: Preliminary Technoeconomic Analysis
8
CVD
Reactor with
Integrated
Furnace
Heat
Exchanger
Sacrificial
Catalyst
CNF coated
Silica Fume
580 mt/yr
Hydrogen
Pump
Natural Gas
Feed
9.7 MMSCF/yr
ParametersNG cost: Free
IRR: 10%
Lifetime: 15 years
Estimated TDC: $1M-2M
Cost of Capital: 8.5%
ResultsCNF coated silica, price range:
$2 - $4 per kg
Pure CNF, price range:
$10 - $20 per kg
Pure CNF, current technology:
$300 per kg (bulk)
Furnace
Exhaust
Challenges and Technical Partnerships
Challenges/Risks
‣ CNF/CNP Synthesis Risk - Particle ALD catalyst will be unable to grow substantial CNF/CNP quantity
‣ Cement Mixing Risks - The produced CNFs/CNPs are not easily homogenized with cement
‣ CVD Reactor Scale-up Risk
‣ Identify technology implementation of CNF/CNP additives
Reducing Risk/Mitigation Strategies
‣ CNF Synthesis Risk Reduction - Metal nanoparticles will be deposited as metals in-situ using ALD with a reduction step, followed by CVD (can be sequenced if desired)
‣ Cement Mixing Risk Reduction – Methods to ensure dispersion will be investigated using detergents and anti-foam agents
‣ Skid Design, Construction, and Operation at Forge Nano
‣ NRMCA will link the research team with potential contacts or organizations and the co-PI will be engaged in committees writing standards for implementation
9
Timeline EERE (Pipeline)
10
I
2020/2021 2021/2022 2022/2023
Timeline: NETL (Flare Gas)
11
1.1 Project Mgt. Plan
1.2 Project Maturation Plan
1.3 TEA
Completed Tasks
Current Tasks
2.1 Lab CVD Construction
3.1 Skid Design
4.1 Concrete Mix Design
Collaborations
12
Fund-Receiving Collaborator Project Roles
ForgeNanoReactor/process design and
technoeconomic analysis
National Ready Mixed
Concrete Association
(NRMCA)
Concrete materials, mix design,
and consulting
Acknowledgements
13
14
What questions do you have?