Long-term coal gasification-based power plants with near-zero emissions. Part A: Zecomix cycle

These two part papers analyse three plant configurations for high efficiency, near-zero emissions power generation from coal, suitable for long-term installations. In the first part the Zecomix cycle, a novel power plant based on various innovative processes, is presented. Zecomix plant is based on a coal hydrogasification process, using recycled steam and hydrogen as gasifying agents, to produce a CH₄ rich syngas. Methane is then converted to an H₂/H₂O based syngas and CO₂ is captured, by reacting in two carbonator reactors with CaO-based solid sorbent. CaCO₃ produced in carbonators is thermally regenerated in a calciner. The synthetic fuel is burned with oxygen in a semi-closed high temperature steam cycle, with a supercritical heat recovery.The paper presents a detailed analysis of the thermodynamic aspects of the process, with the scope of assessing its potential performance in terms of efficiency and emissions. Main operating parameters of the chemical island (e.g. hydrogasifier and calciner pressure, steam flow rates to carbonators, syngas recycle fraction) and of the power island (e.g. pressure ratio, turbine inlet temperature and reheat pressure) were varied in order to evaluate their effect on plant performance and to optimize the process. Critical issues are specifically discussed: the calcination process, the calcium oxide utilization in carbonators, the cooling requirement of the high temperature turbine, the presence of incondensable species in the steam cycle. An accurate performance estimation is therefore developed by considering advanced components, as an evolution of today's technology, excluding unproven devices whose feasibility cannot be anticipated.Depending on sorbent utilization, a net plant efficiency of 44–47% with a virtually complete carbon capture was obtained, a very interesting result with respect to other proposed coal-fired power plants with carbon capture. The high complexity of the chemical island and the importance of a good sorbent performance should be however taken into account for a fair comparison with other plant concepts. Further experimental investigations are mandatory to demonstrate the technical and economical feasibility of the Zecomix plant.