Design and off-design analyses of a pre-combustion CO2 capture process in a natural gas combined cycle power plant

In this study, a cycle designed for capturing the greenhouse gas CO₂ in a natural gas combined cycle power plant has been analyzed. The process is a pre-combustion CO₂ capture cycle utilizing reforming of natural gas and removal of the carbon in the fuel prior to combustion in the gas turbine. The power cycle consists of a H₂-fired gas turbine and a triple pressure steam cycle. Nitrogen is used as fuel diluent and steam is injected into the flame for additional NO_x control. The heat recovery steam generator includes pre-heating for the various process streams. The pre-combustion cycle consists of an air-blown auto-thermal reformer, water–gas shift reactors, an amine absorption system to separate out the CO₂, as well as a CO₂ compression block. Included in the thermodynamic analysis are design calculations, as well as steady-state off-design calculations. Even though the aim is to operate a plant, as the one in this study, at full load there is also a need to be able to operate at part load, meaning off-design analysis is important. A reference case which excludes the pre-combustion cycle and only consists of the power cycle without CO₂ capture was analyzed at both design and off-design conditions for comparison. A high degree of process integration is present in the cycle studied. This can be advantageous from an efficiency stand-point but the complexity of the plant increases. The part load calculations is one way of investigating how flexible the plant is to off-design conditions. In the analysis performed, part load behavior is rather good with efficiency reductions from base load operation comparable to the reference combined cycle plant.     

Evaluation of different CHP options for refinery integration in the context of a low carbon future

This study presents a comparison of different concepts for delivering combined heat and power (CHP) to a refinery in Norway. A reference case of producing high pressure steam from natural gas in boilers and electricity in a combined cycle power plant, is compared to a: (1) natural gas fueled CHP without any CO₂ capture; (2) hydrogen fueled CHP with hydrogen produced from steam methane reforming (SMR); (3) hydrogen fueled CHP with hydrogen produced from autothermal reforming (ATR); and finally (4) natural gas fueled CHP with postcombustion CO₂ removal. The options are compared on the basis of first law efficiency, emissions of CO₂ and a simplified cash flow evaluation. Results show that in terms of efficiency the standard natural gas fueled CHP performs better than the reference case as well as the options with carbon capture. The low carbon options in turn offer lower emissions of greenhouse gases while maintaining the same efficiency as the reference case. The cash flow analysis shows that for any option, a certain mix of prices is required to produce a positive cash flow. As expected, the relationship between natural gas price and electricity price affects all options. Also the value of heat and CO₂ emissions plays an important role.     

CO2 capture from combined cycles integrated with Molten Carbonate Fuel Cells

In this paper Molten Carbonate Fuel Cells (MCFCs) are considered for their potential application in carbon dioxide separation when integrated into natural gas fired combined cycles. The MCFC performs on the anode side an electrochemical oxidation of natural gas by means of CO₃^2? ions which, as far as carbon capture is concerned, results in a twofold advantage: the cell removes CO₂ fed at the cathode to promote carbonate ion transport across the electrolyte and any dilution of the oxidized products is avoided.The MCFC can be “retrofitted” into a combined cycle, giving the opportunity to remove most of the CO₂ contained in the gas turbine exhaust gases before they enter the heat recovery steam generator (HRSG), and allowing to exploit the heat recovery steam cycle in an efficient “hybrid” fuel cell + steam turbine configuration. The carbon dioxide can be easily recovered from the cell anode exhaust after combustion with pure oxygen (supplied by an air separation unit) of the residual fuel, cooling of the combustion products in the HRSG and water separation. The resulting power cycle has the potential to keep the overall cycle electrical efficiency approximately unchanged with respect to the original combined cycle, while separating 80% of the CO₂ otherwise vented and limiting the size of the fuel cell, which contributes to about 17% of the total power output so that most of the power capacity relies on conventional low cost turbo-machinery. The calculated specific energy for CO₂ avoided is about 4 times lower than average values for conventional post-combustion capture technology. A sensitivity analysis shows that positive results hold also changing significantly a number of MCFC and plant design parameters.     

Techno-economic study of CO2 capture from natural gas based hydrogen plants

Canadian oil sands are considered to be the second largest oil reserves in the world. However, the upgrading of bitumen from oil sands to synthetic crude oil (SCO) requires nearly ten times more hydrogen (H₂) than conventional crude oils. The current H₂ demand for oil sands operations is met mostly by steam reforming of natural gas (SMR). The future expansion of oil sands operations is likely to quadruple the demand of H₂ for oil sand operations in the next decade.This paper presents modified process schemes that capture CO₂ at minimum energy penalty in modern SMR plants. The approach is to simulate a base case H₂ plant without CO₂ capture and then look for the best operating conditions that minimize the energy penalty associated with CO₂ capture while maximizing H₂ production. The two CO₂ capture schemes evaluated in this study include a membrane separation process and the monoethanolamine (MEA) absorption process. A low energy penalty is observed when there is lower CO₂ production and higher steam production. The process simulation results show that the H₂ plant with CO₂ capture has to be operated at lower steam to carbon ratio (S/C), higher inlet temperature of the SMR and lower inlet temperatures for the water gas-shift (WGS) converters to attain lowest energy penalty. Also it is observed that both CO₂ capture processes, the membrane process and the MEA absorption process, are comparable in terms of energy penalty and CO₂ avoided when both are operated at conditions where lowest energy penalty exists.     

Integration of CO2 capture unit using single- and blended-amines into supercritical coal-fired power plants: Implications for emission and energy management

This work provides the essential information and approaches for integration of carbon dioxide (CO₂) capture units into power plants, particularly the supercritical type, so that energy utilization and CO₂ emissions can be well managed in the subject power plants. An in-house model, developed at the University of Regina, Canada, was successfully used for simulating a 500 MW supercritical coal-fired power plant with a post-combustion CO₂ capture unit. The simulations enabled sensitivity and parametric study of the net efficiency of the power plant, the coal consumption rate, and the amounts of CO₂ captured and avoided. The parameters of interest include CO₂ capture efficiency, type of coal, flue gas delivery scheme, type of amine used in the capture unit, and steam pressure supplied to the capture unit for solvent regeneration. The results show that the advancement of MEA-based CO₂ capture units through uses of blended monoethanolamine–methyldiethanolamine (MEA–MDEA) and split flow configuration can potentially make the integration of power plant and CO₂ capture unit less energy intensive. Despite the increase in energy penalty, it may be worth capturing CO₂ at a higher efficiency to achieve greater CO₂ emissions avoided. The flue gas delivery scheme and the steam pressure drawn from the power plant to the CO₂ capture unit should be considered for process integration.     

A qualitative reliability and operability analysis of an integrated reforming combined cycle plant with CO2 capture

Most of the current CO₂ capture technologies are associated with large energy penalties that reduce their economic viability. Efficiency has therefore become the most important issue when designing and selecting power plants with CO₂ capture. Other aspects, like reliability and operability, have been given less importance, if any at all, in the literature.This article deals with qualitative reliability and operability analyses of an integrated reforming combined cycle concept. The plant reforms natural gas into a syngas, the carbon is separated out as CO₂ after a water-gas shift section, and the hydrogen-rich fuel is used for a gas turbine. The qualitative reliability analysis in the article consists of a functional analysis followed by a failure mode, effects, and criticality analysis (FMECA). The operability analysis introduces the comparative complexity indicator (CCI) concept.Functional analysis and FMECA are important steps in a system reliability analysis, as they can serve as a platform and basis for further analysis. Also, the results from the FMECA can be interesting for determining how the failures propagate through the system and their effects on the operation of the process. The CCI is a helpful tool in choosing the level of integration and to investigate whether or not to include a certain process feature. Incorporating the analytical approach presented in the article during the design stage of a plant can be advantageous for the overall plant performance.     

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%.     

Power generation with CO2 capture: Technology for CO2 purification

The goal of this paper is to find methodologies for removing a selection of impurities (H₂O, O₂, Ar, N₂, SO_x and NO_x) from CO₂ present in the flue gas of two oxy-combustion power plants fired with either natural gas (467 MW) or pulverized fuel (596 MW). The resulting purified stream, containing mainly CO₂, is assumed to be stored in an aquifer or utilized for enhanced oil recovery (EOR) purposes. Focus has been given to power cycle efficiency i.e.: work and heat requirements for the purification process, CO₂ purity and recovery factor (kg of CO₂ that is sent to storage per kg of CO₂ in the flue gas). Two different methodologies (here called Case I and Case II) for flue gas purification have been developed, both based on phase separation using simple flash units (Case I) or a distillation column (Case II). In both cases purified flue gas is liquefied and its pressure brought to 110 atm prior to storage.Case I: A simple flue gas separation takes place by means of two flash units integrated in the CO₂ compression process. Heat in the process is removed by evaporating the purified liquid CO₂ streams coming out from both flashes. Case I shows a good performance when dealing with flue gases with low concentration of impurities. CO₂ fraction after purification is over 96% with a CO₂ recovery factor of 96.2% for the NG-fired flue gas and 88.1% for the PF-fired flue gas. Impurities removal together with flue gas compression and liquefaction reduces power plant output of 4.8% for the NG-fired flue gas and 11.6% for the PF-fired flue gas. The total amount of work requirement per kg stored CO₂ is 453 kJ for the NG-fired flue gas and 586 kJ for the PF-fired flue gas.Case II: Impurities are removed from the flue gas in a distillation column. Two refrigeration loops (ethane and propane) have been used in order to partially liquefy the flue gas and for heat removal from a partial condenser. Case II can remove higher amounts of impurities than Case I. CO₂ purity prior to storage is over 99%; CO₂ recovery factor is somewhat lower than in Case I: 95.4% for the NG-fired flue gas and 86.9% for the PF-fired flue gas, reduction in the power plant output is similar to Case I.Due to the lower CO₂ recovery factor the total amount of work per kg stored CO₂ is somewhat higher for Case II: 457 kJ for the NG-fired flue gas and 603 kJ for the PF-fired flue gas.     

SE-SMR process performance in CFB reactors: Simulation of the CO2 adsorption/desorption processes with CaO based sorbents

A 3D numerical model for gas–solid flow was developed and used to study the sorption enhanced steam methane reforming (SE-SMR) and the sorbent regeneration processes with CaO based sorbent in fluidized bed reactors. The SE-SMR process (i.e., SMR and adsorption of CO₂) was carried out in a bubbling fluidized bed. The effects of pressure and steam-to-carbon ratio on the reactions are studied. High pressure and low steam-to-carbon ratio will decrease the conversion of methane. But the high pressure makes the adsorption of CO₂ faster. The methane conversion and heat utility are enhanced by CO₂ adsorption. The produced CO₂ in SMR process is adsorbed almost totally in a relative long period of time in the bubbling fluidized bed. It means that the adsorption rate of CO₂ is fast enough compared with the SMR rate. The process of sorbent regeneration was carried out in a riser. An unfeasible residence time is required to complete the regeneration process. Higher temperature makes the release of CO₂ faster, but the rate is severely restrained by the increased CO₂ concentration in gas phase. The temperature distribution is uniform over the whole reactor. Regeneration rate and capacity of sorbents are important factors in selecting the type of reactors for SE-SMR process.     

CO2 capture by adsorption: Materials and process development

Vacuum swing adsorptive (VSA) capture of CO₂ from flue gas and related process streams is a promising technology for greenhouse gas mitigation. Although early reports suggested that VSA was problematic and expensive, through the application of more logical process configurations that are appropriately coupled to the composition of the feed and product gas streams, we can now refute this early assertion. Improved cycle designs coupled with tighter temperature control are also helping to optimise performance for CO₂ separation. Simultaneously, new adsorbent materials are being developed. These separate CO₂ by selective (acid-base) reaction with surface bound amine groups (chemisorption), rather than on the basis of non-bonding interactions (physisorption). This report describes some of these recent developments from our own laboratories and points to synergies that are anticipated as a result of combining these improvements in adsorbent properties and VSA process cycles.     

CO2 capture from pre-combustion processes—Strategies for membrane gas separation

The application of membrane gas separation to CO₂ capture from a coal gasification process is one potential solution to reduce greenhouse gas emissions. This review considers the potential for either H₂- or CO₂-selective membranes in an integrated gasification combined cycle (IGCC) process. In particular, the advantages and disadvantages of metallic, porous inorganic and polymeric membranes are considered. This analysis is extended to consider membrane technology as an enhancement to the water-gas shift reaction, to drive the production of hydrogen above the thermodynamic limit. The review concludes with a brief overview of the economics of incorporating membrane gas separation into the IGCC process and gives an indication of the potential economic use of membrane gas separation technology in the IGCC process.     

Techno-economic evaluation of biogas upgrading process using CO2 facilitated transport membrane

The biogas upgrading by membrane separation process using a highly efficient CO₂-selective polyvinylamine/polyvinylalcohol (PVAm/PVA) blend membrane was investigated by experimental study and simulation with respect to process design, operation optimization and economic evaluation. This blend membrane takes advantages of the unique CO₂ facilitated transport from PVAm and the robust mechanical properties from PVA, exhibits both high CO₂/CH₄ separation efficiency and very good stability. CO₂ transports through the water swollen membrane matrix in the form of bicarbonate. CO₂/CH₄ selectivity up to 40 and CO₂ permeance up to 0.55 m³(STP)/m² h bar at 2 bar were documented in lab with synthesized biogas (35% CO₂ and 65% CH₄). Membrane performances at varying feed pressures were recorded and used as the simulation basis in this work. The process simulation of an on-farm scale biogas upgrading plant (1000 Nm³/h) was conducted. Processes with four different membrane module configurations with or without recycle were evaluated technically and economically, and the 2-stage in cascade with recycle configuration was proven optimal among the four processes. The sensitivity of the process to various operation parameters was analyzed and the operation conditions were optimized.     

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.     

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.     

Reforming of CO2-containing natural gas with steam in AC gliding arc discharge for hydrogen production

In this study, a low-temperature gliding arc discharge system was used to investigate the effects of steam content and operational parameters, i.e. total feed flow rate, applied voltage, and input frequency, on the reforming performance of CO₂-containing natural gas. The addition of steam less than 10% was found to enhance both selectivities for hydrogen and carbon monoxide with a significant reduction of power consumptions. The highest hydrogen selectivity and yield with the lowest power consumptions were achieved at a steam content of 10 mol%, a total feed flow rate of 100 cm³/min (corresponding to a very short residence time of 1.37 s), an applied voltage of 13.5 kV and an input frequency of 300 Hz. Under these optimum conditions, the oxidative dehydrogenation reactions to produce hydrogen were dominant with the minimum activities of all undesired reactions of cracking and coupling. Both of the short residence time (1.37 s) with a low bulk temperature (lower than 200°C) in the plasma zone under atmospheric pressure, indicate that the studied plasma reactor (gliding arc system) is superior to conventional catalytic reactors for reforming of natural gas.     

Multi-stage chemical looping combustion (CLC) for combined cycles with CO2 capture

This paper presents application of the chemical looping combustion (CLC) method in natural gas-fired combined cycles for power generation with CO₂ capture. A CLC combined cycle consisting of single CLC-reactor system, an air turbine, a CO₂-turbine and a steam cycle has been designated as the base-case cycle. The base-case cycle can achieve net plant efficiency of about 52% at an oxidation temperature of 1200 °C. In order to achieve a reasonable efficiency at lower oxidation temperatures, reheat is introduced into the air turbine by employing multi CLC-reactors. The results show that the single reheat CLC-combined cycle can achieve net plant efficiency of above 51% at oxidation temperature of 1000 °C and above 53% at the oxidation temperature of 1200 °C including CO₂ compression to 110 bar. The double reheat cycle results in marginal efficiency improvement as compared to the single reheat cycle. The CLC-cycles are also compared with a conventional combined cycle with and without post-combustion capture in amine solution. All the CLC-cycles show higher net plant efficiencies with close to 100% CO₂ capture as compared to a conventional combined cycle with post-combustion capture, which is very promising.     

Life cycle assessment of carbon dioxide capture and storage from lignite power plants

In this article, we present a life cycle assessment (LCA) of CO₂ capture and storage (CCS) for several lignite power plant technologies. The LCA includes post-combustion, pre-combustion and oxyfuel capture processes as well as subsequent pipeline transport and storage of the separated CO₂ in a depleted gas field.The results show an increase in cumulative energy demand and a substantial decrease in greenhouse gas (GHG) emissions for all CO₂ capture approaches in comparison with power plants without CCS, assuming negligible leakage within the time horizon under consideration. Leakage will, however, not be zero. Due to the energy penalty, CCS leads to additional production of CO₂. However, the CO₂ emissions occur at a much lower rate and are significantly delayed, thus leading to different, and most likely smaller, impacts compared to the no-sequestration case. In addition, a certain share of the CO₂ will be captured permanently due to chemical reactions and physical trapping.For other environmental impact categories, the results depend strongly on the chosen technology and the details of the process. The post-combustion approach, which is closest to commercial application, leads to sharp increases in many categories of impacts, with the impacts in only one category, acidification, reduced. In comparison with a conventional power plant, the pre-combustion approach results in decreased impact in all categories. This is mainly due to the different power generation process (IGCC) which is coupled with the pre-combustion technology.In the case of the oxyfuel approach, the outcome of the LCA depends highly on two uncertain parameters: the energy demand for air separation and the feasibility of co-capture of pollutants other than CO₂. If co-capture were possible, oxyfuel could lead to a near-zero emission power plant.     

Designing a supercritical steam cycle to integrate the energy requirements of CO2 amine scrubbing

Absorption by chemical solvents combined with CO₂ long-term storage appears to offer interesting and commercial applicable CO₂ capture technology. However one of the main disadvantages is related to the large quantities of heat required to regenerate the amine solvent that means an important power plant efficiency penalty. Different studies have analyzed alternatives to reduce the heat duty on the reboiler and the thermal integration requirements on existing power cycles. In these studies integration principles have been well set up, but there is a lack of information about how to achieve an integrated design and the thermal balances of the modified cycle flowsheet. This paper proposes and provides details about a set of modifications of a supercritical steam cycle to overcome the energy requirements through energetic integration with the aim of reducing the efficiency and power output penalty associated with CO₂ capture process. Modifications include a new designed low-pressure heater flowsheet to take advantage of the CO₂ compression cooling for postcombustion systems and integration of amine reboiler into a steam cycle. It has been carried out several simulations in order to obtain power plant performance depending on sorbent regeneration requirements.     

Long-term coal gasification-based power with near-zero emissions. Part B: Zecomag and oxy-fuel IGCC cycles

In this second part of the work, two other long-term technologies for power generation from coal are investigated. The Zecomag plant has the same syngas production system of the Zecomix plant, described in the first part of this paper, but hydrogen-rich syngas is here burned with air in an open-cycle gas turbine. The aim is a simplification of the power island, more similar to a combined cycle; however, CO₂ capture falls from 100% to about 90% and NO_x emissions are present.An advanced oxy-fuel IGCC is the second plant investigated in this paper, presenting the same zero-emission potential of Zecomix. Syngas is produced in a high pressure, dry feed, oxygen blown gasifier and cleaned in a hot-gas-clean-up system. Clean syngas is then burned with oxygen and expanded in a turbine, using compressed recirculated CO₂ to moderate firing temperature and to cool turbine blades.The loss of net efficiency, with respect to Zecomix, is very limited (1–2 points) with both configurations. In order to better evaluate the performances obtained, a comparison with reference state-of-the art IGCCs and a long-term IGCC without CO₂ capture is also presented.     

The modelling of a hybrid combined cycle with pressurised fluidised bed combustion and CO2 capture

This study investigates the possibility of capturing CO₂ from flue gas under pressurised conditions, which could prove to be beneficial in comparison to working under atmospheric conditions. Simulations of two hybrid combined cycles with pressurised fluidised bed combustion and CO₂ capture are presented. CO₂ is captured from pressurised flue gas by means of chemical absorption after the boiler but before expansion. The results show a CO₂ capture penalty of approximately 8 percentage points (including 90% CO₂ capture rate and compression to 110 bar), which makes the efficiency for the best performing cycle 43.9%. It is 5.2 percentage points higher than the most probable alternative, i.e. using a natural gas fired combined cycle and a pulverised coal fired condensing plant separately with the same fuel split ratio. The largest part of the penalty is associated with the lower mass flow of flue gas after CO₂ capture, which leads to a decrease in work output in the expander and potential for feed water heating. The penalty caused by the regeneration of absorbent is quite low, since the high pressure permits the use of potassium carbonate, which requires less regeneration heat than for example the more commonly proposed monoethanolamine. Although the efficiencies of the cycles look promising it will be important to perform a cost estimate to be able to make a fair comparison with other systems. Such a cost estimate has not been done in this study. A significant drawback of these hybrid cycles in that respect is the complex nature of the systems that will have a negative effect on the economy.