Techno-Economic Study of CO2 Capture from an Existing Cement Plant Using MEA Scrubbing

Carbon dioxide is the major greenhouse gas responsible for global warming. Man-made CO₂ emissions contribute approximately 63% of greenhouse gases and the cement industry is responsible for approximately 5% of CO₂ emissions emitting nearly 900 kg of CO₂ per 1000 kg of cement. CO₂ from a cement plant was captured and purified to 98% using the monoethanolamine (MEA) based absorption process. The capture cost was $51 per tonne of CO₂ captured, representing approximately 90% of total cost. Steam was the main operating cost representing 39% of the total capture cost. Switching from coal to natural gas reduces CO₂ emissions by about 18%. At normal load, about 36 MW of waste heat is available for recovery to satisfy the parasitic heat requirements of MEA process; however, it is very difficult to recover.     

Methodology for CO2 chain analysis

The paper presents a methodology for CO₂ chain analysis with particular focus on the impact of technology development on the total system economy. The methodology includes the whole CO₂ chain; CO₂ source, CO₂ capture, transport and storage in aquifers or in oil reservoirs for enhanced oil recovery. It aims at supporting the identification of feasible solutions and assisting the selection of the most cost-effective options for carbon capture and storage. To demonstrate the applicability of the methodology a case study has been carried out to illustrate the possible impact of technology improvements and market development. The case study confirms that the CO₂-quota price to a large extent influence the project economy and dominates over potential technology improvements. To be economic feasible, the studied chains injecting the CO₂ in oil reservoirs for increased oil production require a CO₂-quota price in the range of 20–27 €/tonne CO₂, depending on the technology breakthrough. For the chains based on CO₂ storage in saline aquifers, the corresponding CO₂-quota price varies up to about 40 €/tonne CO₂.     

Pipeline design for a least-cost router application for CO2 transport in the CO2 sequestration cycle

CO₂ capture and geological storage (CCS) is considered as a viable option to mitigate greenhouse gas emissions during the transition phase towards the use of clean and renewable energy. This paper concentrates on the transport of CO₂ between source (CO₂ capture at plants) and sink (geological storage reservoirs). In the cost estimation of CO₂ transport, the pipeline diameter plays an important role. In this respect, the paper reviews equations that were used in several reports on CO₂ pipeline transport. As some parameters are not taken into account in these equations, alternative formulas are proposed which calculate the proper inner diameter size based on flow rate, pressure drop per unit length, CO₂ density, CO₂ viscosity, pipeline material roughness and topographic height differences (the Darcy–Weisbach solution) and, in addition, on the amount and type of bends (the Manning solution). Comparison between calculated diameters using the reviewed and the proposed equations demonstrate the important influence of elevation difference (which is not considered in the reviewed equations) and pipeline material roughness-related factor on the calculated diameter. Concerning the latter, it is suggested that a Darcy–Weisbach roughness height of 0.045 mm better corresponds to a Manning factor of 0.009 than higher Manning values previously proposed in literature. Comparison with the actual diameter of the Weyburn pipeline confirms the accuracy of the proposed equations. Comparison with other existing CO₂ pipelines (without pressure information) indicate that the pipelines are designed for lower pressure gradients than 25 Pa/m or for (future) higher flow rates. The proposed Manning equation is implemented in an economic least-cost route planner in order to obtain the best economic solution for pipeline trajectory and corresponding diameter.     

Life cycle assessment of a pulverized coal power plant with post-combustion capture, transport and storage of CO2

In this study the methodology of life cycle assessment has been used to assess the environmental impacts of three pulverized coal fired electricity supply chains with and without carbon capture and storage (CCS) on a cradle to grave basis. The chain with CCS comprises post-combustion CO₂ capture with monoethanolamine, compression, transport by pipeline and storage in a geological reservoir. The two reference chains represent sub-critical and state-of-the-art ultra supercritical pulverized coal fired electricity generation. For the three chains we have constructed a detailed greenhouse gas (GHG) balance, and disclosed environmental trade-offs and co-benefits due to CO₂ capture, transport and storage. Results show that, due to CCS, the GHG emissions per kWh are reduced substantially to 243 g/kWh. This is a reduction of 78 and 71% compared to the sub-critical and state-of-the-art power plant, respectively. The removal of CO₂ is partially offset by increased GHG emissions in up- and downstream processes, to a small extent (0.7 g/kWh) caused by the CCS infrastructure. An environmental co-benefit is expected following from the deeper reduction of hydrogen fluoride and hydrogen chloride emissions. Most notable environmental trade-offs are the increase in human toxicity, ozone layer depletion and fresh water ecotoxicity potential for which the CCS chain is outperformed by both other chains. The state-of-the-art power plant without CCS also shows a better score for the eutrophication, acidification and photochemical oxidation potential despite the deeper reduction of SO_x and NO_x in the CCS power plant. These reductions are offset by increased emissions in the life cycle due to the energy penalty and a factor five increase in NH₃ emissions.     

Effective retrofitting of post-combustion CO2 capture to coal-fired power plants and insensitivity of CO2 abatement costs to base plant efficiency

Existing coal-fired power plants were not designed to be retrofitted with carbon dioxide post-combustion capture (PCC) and have tended to be disregarded as suitable candidates for carbon capture and storage on the grounds that such a retrofit would be uneconomical. Low plant efficiency and poor performance with capture compared to new-build projects are often cited as critical barriers to capture retrofit. Steam turbine retrofit solutions are presented that can achieve effective thermodynamic integration between a post-combustion CO₂ capture plant and associated CO₂ compressors and the steam cycle of an existing retrofitted unit for a wide range of initial steam turbine designs. The relative merits of these capture retrofit integration options with respect to flexibility of the capture system and solvent upgradability will be discussed. Provided that effective capture system integration can be achieved, it can be shown that the abatement costs (or cost per tonne of CO₂ to justify capture) for retrofitting existing units is independent of the initial plant efficiency. This then means that a greater number of existing power plants are potentially suitable for successful retrofits of post-combustion capture to reduce power sector emissions. Such a wider choice of retrofit sites would also give greater scope to exploit favourable site-specific conditions for CCS, such as ready access to geological storage.     

CO2 capture from power plants: Part II. A parametric study of the economical performance based on mono-ethanolamine

While the demand for reduction in CO₂ emission is increasing, the cost of the CO₂ capture processes remains a limiting factor for large-scale application. Reducing the cost of the capture system by improving the process and the solvent used must have a priority in order to apply this technology in the future. In this paper, a definition of the economic baseline for post-combustion CO₂ capture from 600 MW_e bituminous coal-fired power plant is described. The baseline capture process is based on 30% (by weight) aqueous solution of monoethanolamine (MEA). A process model has been developed previously using the Aspen Plus simulation programme where the baseline CO₂-removal has been chosen to be 90%. The results from the process modelling have provided the required input data to the economic modelling. Depending on the baseline technical and economical results, an economical parameter study for a CO₂ capture process based on absorption/desorption with MEA solutions was performed.Major capture cost reductions can be realized by optimizing the lean solvent loading, the amine solvent concentration, as well as the stripper operating pressure. A minimum CO₂ avoided cost of € 33 tonne⁻¹ CO₂ was found for a lean solvent loading of 0.3 mol CO₂/mol MEA, using a 40 wt.% MEA solution and a stripper operating pressure of 210 kPa. At these conditions 3.0 GJ/tonne CO₂ of thermal energy was used for the solvent regeneration. This translates to a € 22 MWh⁻¹ increase in the cost of electricity, compared to € 31.4 MWh⁻¹ for the power plant without capture.     

Gas conditioning—The interface between CO2 capture and transport

Gas conditioning is commonly referred to as the required processing for a produced natural gas to achieve transport and sales specifications. In this paper, gas conditioning as the processing required in the interface between CO₂ capture and transport is studied for nine different natural gas fired power plant concepts and three different CO₂ transport processes. Conditioning processes for both pipeline and ship transport are described and an enhanced process for volatile removal is developed. The energy requirement for the conditioning processes is normally between 90 and 120 kWh/tonne CO₂; however, this depends on the pressure and composition of the captured CO₂-rich stream. The loss of CO₂ in the water purge is small for most capture processes. The waste streams from the gas conditioning processes can contain large amounts of CO₂ and should therefore be further processed or reintroduced at an appropriate point upstream in the capture or gas conditioning process if possible. The integration benefit may vary depending on the composition of the CO₂-rich stream. It could be particularly interesting for processes with “innovative reactors” (membranes, sorbents, chemical looping) to integrate CO₂ capture and gas conditioning.     

Performance of amine-multilayered solid sorbents for CO2 removal: Effect of fabrication variables

The emission of fossil fuel carbon dioxide (CO₂) to the atmosphere is implicated as the predominant cause of global climate change; therefore, advanced CO₂ capture technologies are of the utmost importance. In this study, innovative amine-multilayered sorbents were fabricated using layer-by-layer (LbL) nanoassembly technology via alternate deposition of a CO₂-adsorbing amine polymer (e.g. polyethylenimine or PEI) and an oppositely-charged polymer (e.g. polystyrene sulfonate or PSS). We found that the developed sorbents could be used for CO₂ capture and that LbL nanoassembly allows us to engineer their CO₂ capture performance through the fabrication variables (e.g. deposition polymers, deposition media, and number of bilayers). PEI/PSS was found to be the best polymer combination for developing sorbents with relatively high CO₂ capture capacity. The amine-multilayered solid sorbents possessed fine microstructures and may have similar polymer deposition within and on the surface of solid sorbents. These amine-multilayered sorbents had much faster CO₂ desorption rates compared to sorbents prepared using the current PEI-impregnation approach. Such fast CO₂ desorption could make sorbents a good option for CO₂ removal from power plants and even the atmosphere.     

Economic evaluation of the geological storage of CO2 considering the scale of economy

CO₂ capture and storage (CCS) technology is expected to play an important role in the efforts directed toward long-term CO₂ emission reduction. This paper analyzes the cost of the geological storage of CO₂ in Japan in order to consider future research, development and deployment (RD&D); these would be based on the information of the obtained cost structure. According to the analysis results, the costs, particularly those of the transportation by pipeline and of CO₂ injection, strongly depend on the scale of the facilities. Therefore, the distance of the transportation of CO₂ should be minimized in the case of small-scale storage, particularly in Japan. In addition, the potential injection rate per well is another key factor for the injection cost. Based on the analyzed cost, the injection cost of the geological storage of CO₂ in Japan for individual storage sites is estimated, and the cost–potential curve is obtained. A mixed-integer programming model has been developed to take into account these characteristics of the CCS technology and its adverse effects arising from the scale of economy with regard to the transportation and injection cost for the geological storage of CO₂. The model is designed to evaluate CCS and other CO₂ mitigation technologies in the energy systems of Japan. With all these adverse effects due to the scale of economy, the geological storage of CO₂ will be one of the important options for CO₂ emission reduction in Japan.     

Integration of post-combustion capture and storage into a pulverized coal-fired power plant

Post-combustion CO₂ capture and storage (CCS) presents a promising strategy to capture, compress, transport and store CO₂ from a high volume–low pressure flue gas stream emitted from a fossil fuel-fired power plant. This work undertakes the simulation of CO₂ capture and compression integration into an 800 MW_e supercritical coal-fired power plant using chemical process simulators. The focus is not only on the simulation of full load of flue gas stream into the CO₂ capture and compression, but also, on the impact of a partial load. The result reveals that the energy penalty of a low capture efficiency, for example, at 50% capture efficiency with 10% flue gas load is higher than for 90% flue gas load at the equivalent capture efficiency by about 440 kWh_e/tonne CO₂. The study also addresses the effect of CO₂ capture performance by different coal ranks. It is found that lignite pulverized coal (PC)-fired power plant has a higher energy requirement than subbituminous and bituminous PC-fired power plants by 40.1 and 98.6 MW_e, respectively. In addition to the investigation of energy requirement, other significant parameters including energy penalty, plant efficiency, amine flow rate and extracted steam flow rate, are also presented. The study reveals that operating at partial load, for example at half load with 90% CO₂ capture efficiency, as compared with full load, reduces the energy penalty, plant efficiency drop, amine flow rate and extracted steam flow rate by 9.9%, 24.4%, 50.0% and 49.9%, respectively. In addition, the effect of steam extracted from different locations from a series of steam turbine with the objective to achieve the lowest possible energy penalty is evaluated. The simulation shows that a low extracted steam pressure from a series of steam turbines, for example at 300 kPa, minimizes the energy penalty by up to 25.3%.     

Embodied energy and CO2 in UK dimension stone

A process based life cycle assessment of dimension stone production in the UK has been carried out according to PAS 2050. From a survey of eight production operations, on a cradle-to-site basis for UK destinations the carbon footprint of sandstone is 77 kgCO₂e/tonne, that of granite is 107 kgCO₂e/tonne and that of slate is 251 kgCO₂e/tonne. These values are considerably higher for stone imported from abroad due to the impact of transport. Reducing the reliance on imported stone will contribute to emissions reduction targets as well as furthering the goals of sustainable development.     

Energy and carbon dioxide intensity of Thailand's steel industry and greenhouse gas emission projection toward the year 2050

The purpose of this article is to study the energy and carbon dioxide intensities of Thailand's steel industry and to propose greenhouse gas emission trends from the year 2011 to 2050 under plausible scenarios. The amount of CO₂ emission from iron and steel production was calculated using the 2006 Intergovernmental Panel on Climate Change (IPCC) guidelines in the boundary of production process (gate to gate). The results showed that energy intensity of semi-finished steel product was 2.84 GJ/t semi-finished steel and CO₂ intensity was 0.37 tCO_2eq/t semi-finished steel. Energy intensity of steel finishing process was 1.86 GJ/t finished steel and CO₂ intensity was 0.16 tCO_2eq/t finished steel. Using three plausible scenarios from Thailand's steel industry, S1: without integrated steel plant (baseline scenario), S2: with a traditional integrated BF–BOF route and S3: with an alternative integrated DR-EAF route; the Greenhouse Gas emissions from the year 2011 to 2050 were projected. In 2050, the CO₂ emission from S1 (baseline scenario) was 4.84 million tonnes, S2 was 21.96 million tonnes increasing 4.54 times from baseline scenario. The CO₂ emission from S3 was 7.12 million tonnes increasing 1.47 times from baseline scenario.     

Separation and recovery of carbon dioxide by a membrane flash process

A novel process for carbon dioxide (CO₂) separation, which was named a membrane flash process, was developed to realize an energy-saving technology and to substitute it for a conventional regenerator. The electric energy for CO₂ recovery in a membrane flash process using aluminum oxide and diethanolamine was lower than the thermal energy of the conventional chemical absorption process. Flashing at elevated temperature by the low temperature energy significantly reduced the electric energy and required much less membrane area. This process has potentiality of low cost capture of CO₂ when the low temperature energy, which is not available for other purposes, can be utilized to elevate flashing temperature.     

Effect of steam hydration on performance of lime sorbent for CO2 capture

Lime is considered a feasible sorbent for the capture of CO₂ from large stationary sources. The positive attributes of a natural source material, low cost and lack of harmful by-products are offset by rapid deterioration in performance and high regeneration temperature. Performance can be improved by hydrating the lime using steam. We investigate a steam hydration process wherein lime is hydrated for 5 min at 300 °C and atmospheric pressure in a mixture of steam and CO₂. The experiments consisted of 10 capture cycles with 60% of the lime active at the end. Extrapolation using a decay model suggests a residual carbonation level of 48%, significantly higher than the 8% achieved by dry lime cycles. The cost of replacement sorbent under these conditions is less than $1/t of CO₂ captured. The hydrated lime process also reduces the thermal load, for heating and cooling, by half as well as the inventory, and therefore solids handling, by a factor 5 over dry lime. The introduction of the hydration reaction provides another exothermic reaction for heat management.     

Use of experience curves to estimate the future cost of power plants with CO2 capture

Given the dominance of power plant emissions of greenhouse gases, and the growing worldwide interest in CO₂ capture and storage (CCS) as a potential climate change mitigation option, the expected future cost of power plants with CO₂ capture is of significant interest. Reductions in the cost of technologies as a result of learning-by-doing, R&D investments and other factors have been observed over many decades. This study uses historical experience curves as the basis for estimating future cost trends for four types of electric power plants equipped with CO₂ capture systems: pulverized coal (PC) and natural gas combined cycle (NGCC) plants with post-combustion CO₂ capture; coal-based integrated gasification combined cycle (IGCC) plants with pre-combustion capture; and coal-fired oxyfuel combustion for new PC plants. We first assess the rates of cost reductions achieved by other energy and environmental process technologies in the past. Then, by analogy with leading capture plant designs, we estimate future cost reductions that might be achieved by power plants employing CO₂ capture. Effects of uncertainties in key parameters on projected cost reductions also are evaluated via sensitivity analysis.     

Geological storage of CO2 in saline aquifers—A review of the experience from existing storage operations

The experience from CO₂ injection at pilot projects (Frio, Ketzin, Nagaoka, US Regional Partnerships) and existing commercial operations (Sleipner, Snøhvit, In Salah, acid-gas injection) demonstrates that CO₂ geological storage in saline aquifers is technologically feasible. Monitoring and verification technologies have been tested and demonstrated to detect and track the CO₂ plume in different subsurface geological environments. By the end of 2008, approximately 20 Mt of CO₂ had been successfully injected into saline aquifers by existing operations. Currently, the highest injection rate and total storage volume for a single storage operation are approximately 1 Mt CO₂/year and 25 Mt, respectively. If carbon capture and storage (CCS) is to be an effective option for decreasing greenhouse gas emissions, commercial-scale storage operations will require orders of magnitude larger storage capacity than accessed by the existing sites. As a result, new demonstration projects will need to develop and test injection strategies that consider multiple injection wells and the optimisation of the usage of storage space. To accelerate large-scale CCS deployment, demonstration projects should be selected that can be readily employed for commercial use; i.e. projects that fully integrate the capture, transport and storage processes at an industrial emissions source.     

Assessing the economic feasibility of regional deep saline aquifer CO2 injection and storage: A geomechanics-based workflow applied to the Rose Run sandstone in Eastern Ohio, USA

Typical top-down regional assessments of CO₂ storage feasibility are sufficient for determining the maximum volumetric capacity of deep saline aquifers. However, they do not reflect the regional economic feasibility of storage. This is controlled, in part, by the number and type of injection wells that are necessary to achieve regional CO₂ storage goals. In contrast, the geomechanics-based assessment workflow that we present in this paper follows a bottom-up approach for evaluating regional deep saline aquifer CO₂ storage feasibility. The CO₂ storage capacity of an aquifer is a function of its porous volume as well as its CO₂ injectivity. For a saline aquifer to be considered feasible in this assessment it must be able to store a specified amount of CO₂ at a reasonable cost per ton of CO₂. The proposed assessment workflow has seven steps that include (1) defining the storage project and goals, (2) characterizing the geology and developing a geomechanical model of the aquifer, (3) constructing 3D aquifer models, (4) simulating CO₂ injection, (5,6) evaluating CO₂ injection and storage feasibility (with and without injection well stimulation), and (7) determining whether it is economically feasible to proceed with the storage project. The workflow was applied to a case study of the Rose Run sandstone aquifer in the Eastern Ohio River Valley, USA. We found that it is feasible in this region to inject 113 Mt CO₂/year for 30 years at an associated well cost of less than US $1.31/t CO₂, but only if injectivity enhancement techniques such as hydraulic fracturing and injection induced micro-seismicity are implemented.     

Optimization of a membrane process for CO2 capture in the steelmaking industry

Three different types of membranes were experimentally evaluated for CO₂ recovery from blast furnace effluents: semi-commercial adsorption selective carbon membranes, in-house tailored carbon molecular sieving membranes, and fixed site carrier (FSC) membranes with amine groups in the polymer backbone for active transport of CO₂. In the single gas experiments the FSC membranes showed superior selectivity for CO₂ over the other relevant gases (CO, N₂ and H₂) and high CO₂ permeance (productivity). In addition, it is easy to process and handle, relatively inexpensive to produce and the water in the feed gas is an advantage rather than a problem, since the membrane must be humidified during operation. Based on these experiments a simulation study of a full scale process was performed. The technology showed notable low energy cost, even when converted to the thermal equivalent. Total costs for the CO₂ recovery unit (CO₂ prepared for pipeline transport) were estimated to be in the range 15.0–17.5 €/tonnes CO₂.     

CO2 capture and storage from a bioethanol plant: Carbon and energy footprint and economic assessment

Biomass energy and carbon capture and storage (BECCS) can lead to a net removal of atmospheric CO₂. This paper investigates environmental and economic performances of CCS retrofit applied to two mid-sized refineries producing ethanol from sugar beets. Located in the Region Centre France, each refinery has two major CO₂ sources: fermentation and cogeneration units. “carbon and energy footprint” (CEF) and “discounted cash flow” (DCF) analyses show that such a project could be a good opportunity for CCS early deployment. CCS retrofit on fermentation only with natural gas fired cogeneration improves CEF of ethanol production and consumption by 60% without increasing much the non renewable energy consumption. CCS retrofit on fermentation and natural gas fired cogeneration is even more appealing by decreasing of 115% CO₂ emissions, while increasing non renewable energy consumption by 40%. DCF shows that significant project rates of return can be achieved for such small sources if both a stringent carbon policy and direct subsidies corresponding to 25% of necessary investment are assumed. We also underlined that transport and storage cost dilution can be realistically achieved by clustering emissions from various plants located in the same area. On a single plant basis, increasing ethanol production can also produce strong economies of scale.