Co2 Capture Technologies PCC
Co2 Capture Technologies PCC
Energy
journal homepage: www.elsevier.com/locate/energy
a r t i c l e i n f o a b s t r a c t
Article history: Oxy-fuel combustion technology is an attractive option for capturing carbon dioxide (CO2) in power
Received 18 October 2009 generation systems utilizing hydrocarbon fuels. However, conventional atmospheric oxy-fuel combus-
Received in revised form tion systems require substantial parasitic energy in the compression step within the air separation unit
9 July 2010
(ASU), the flue gas recirculation system and the carbon dioxide purification and compression unit (CPU).
Accepted 12 July 2010
Available online 16 August 2010
Moreover, a large amount of flue gas latent enthalpy, which has high water concentration, is wasted. Both
lower the overall cycle efficiency. Pressurized oxy-fuel combustion power cycles have been investigated
as alternatives. Our previous study showed the importance of operating pressure for these cycles. In this
Keywords:
Oxy-fuel combustion
paper, as the extended work of our previous study, we perform a pressure sensitivity analysis to
Power cycle analysis determine the optimal combustor operating pressure for the pressurized oxy-fuel combustion power
CO2 capture and sequestration cycle. We calculate the energy requirements of the ASU and the CPU, which vary in opposite directions as
the combustor operating pressure is increased. We also determine the pressure dependence of the water-
condensing thermal energy recovery and its relation to the gross power output. The paper presents
a detailed study on the variation of the thermal energy recovery rate, the overall compression power
demand, the gross power output and the overall net efficiency.
Ó 2010 Elsevier Ltd. All rights reserved.
0360-5442/$ e see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2010.07.016
5392 J. Hong et al. / Energy 35 (2010) 5391e5399
the pressurized oxy-fuel system, oxygen is pre-compressed in the paper [22]. Aspen PropertiesÒ provides thermodynamic and
ASU where the mass flow rate is smaller than that of the flue gases transport properties used to estimate the pressure drop through
into the compression unit (CPU). By pre-compressing the gas the flue gas recirculation path, as explained in Section 2.2.1
stream in the ASU, the combustion flue gases are at the high
pressure and the compression work duty of the CPU, which 2.1. Base case and design variables
compresses the flue gases from the combustor operating pressure
to 110 bars, decreases. Imposing more compression work duty on The pressure sensitivity analysis was performed using the base
the ASU and less on the CPU, the overall system lowers the parasitic case we developed in our previous study [13,22], which is revised to
power demand. Moreover, the energy penalty associated with the adopt the best available technologies especially in a steam cycle
oxygen compression work required to feed oxygen into the pres- and the CPU. The base case plant consists of five primary units, the
surized combustor is partially offset by removing the pre-heater ASU, a pressurized coal combustor, a steam generation unit,
from the oxygen compression line, hence avoiding the thermal a power island and the CPU. Each unit represents commercially
energy penalty related to oxygen pre-heating. In addition, the available technologies or processes at an advanced development
elevated dew point and higher available latent enthalpy in the flue stage. Fig. 1 shows the overall process diagram for the base case
gases lead to higher thermal energy recovery from the flue gases. cycle for the pressurized oxy-fuel combustion system. As shown in
The available latent enthalpy is defined as the recoverable amount Fig. 1, after being compressed by the first feedwater pump, the
of the latent enthalpy of the water in the flue gases (hot stream) condensate recuperates most of the latent enthalpy in the flue
based on the inlet and outlet temperatures of the feedwater (cold gases while flowing the acid condenser. The condensate stream is
stream) across the heat exchanger. The increased water-condensing heated further by cooling the combustor walls. The feedwater
thermal energy recovery enables the system to produce more gross heating system and the HRSG receive the condensate stream, which
power by eliminating the steam bleeding from the low-pressure is compressed to the supercritical state by the second feedwater
steam turbines. Compared to a conventional atmospheric oxy-fuel pump, and generates supercritical steam. On the gas side which is
combustion system, the pressurized system was shown to be more represented by the red lines, the oxygen stream is mixed with the
efficient, taking advantage of lower overall compression work re-circulated flue gases before entering the pressurized oxy-coal
demand and higher gross power output. combustor. The combustion flue gases are cooled down by the
Moreover, our study showed that the fan compression work has secondary recycled flue gases. Passing through the HRSG and
a significant impact on the overall performance. Most oxy-fuel the acid condenser, the flue gases transfer thermal energy to the
combustion systems have implemented recirculation of the flue feedwater. At the end, the flue gas stream is purified and
gases to decrease the combustion temperature to a reasonable compressed by the CPU.
level. Thus, a significant amount of the flue gases is re-circulated The proposed system has two important updates in the power
within the system, requiring a substantial amount of energy to island and the CPU, compared to the pressurized oxy-fuel power
compensate for the pressure drop across the steam generation unit cycle analyzed in our previous study. Because the double reheat
and the recirculation pipe. This feature is even more important for steam cycle is not economically beneficial, it is believed to be a non-
the combustion technology patented by ITEA [7e9], which adopts viable option in conventional coal-fired power plants. Thus, we
two flue gas recycling lines employed to control the combustion updated the previous base case by replacing it with a single reheat
temperature and temperature at the HRSG inlet. steam cycle. We also found that the turbines used in the previous
Based on the finding from the previous study, we have study represent 20-year-old technologies and have lower isen-
concluded that the combustor operating pressure has a strong tropic efficiencies. In this regard, the power island is modified to
impact on the overall performance of the oxy-fuel system. In this utilize the best available steam turbines based on a reference ENEL
paper, we perform a pressure sensitivity analysis to find the optimal power plant that has been recently commissioned. Data provided
combustor operating pressure. We calculate the pressure depen- by ENEL also accounts for the pressure drop along the steam
dence of the thermal energy recovery rate, the overall parasitic bleeding line to the feedwater heaters. In addition, for CO2
power demand, the gross power output and the overall efficiency. production or for Enhanced Oil Recovery (EOR) applications, it is
The analysis enables us to determine which parameters are common to pressurize CO2 by a pump above 80 bars, which is
important in operating the pressurized system and to examine how beyond the CO2 critical point [23]. The previous CPU utilizes only
to improve the overall performance. The methodology used in the compressors in the CO2 compression steps. Therefore, the updated
study is explained in Section 2, and the detailed results are dis- CPU includes a pump as well as compressors to pressurize the CO2
cussed in Section 3. Section 4 includes conclusions. stream up to the delivery pressure of 110 bars. Other detailed
information on the overall processes and coal analysis data can be
2. Methodology found in our previous paper [22].
Based on the base case processes, we fixed a set of important
A 300 MWe coal-fired power plant, which is based on the fixed design variables to focus on system’s operating pressure dependence.
coal flow rate of 30 kg/s corresponding to 874.6 MWth higher Table 1 shows the design variables used in the pressure sensitivity
heating value (HHV) or 839.1 MWth lower heating value (LHV), is analysis. While the gas side variables describe the characteristics
used as the base case for the pressure sensitivity analysis. In the of the available ASU, the combustor and the HRSG, parameters in
previous study, we proposed the pressurized oxy-fuel combustion the steam side represent the supercritical Rankine cycle.
power cycle and discussed its characteristics. The cycle has been
modified to include the best available technologies; all important 2.2. Pressure drop estimation method
design variables are shown in Section 2.1. The combustor operating
pressure was controlled by changing the oxygen delivery pressure As explained in the previous section, the fan compression works
to the combustor from 1.238 bars to 30 bars. The proposed for the flue gas recirculation system accounts for a significant
approach will be explained and discussed in the following sections.
Two commercial simulation packages, ThermoflexÒ and Aspen
PlusÒ, were used to conduct the study. An integration method 1
ThermoflexÒ, Aspen PlusÒ and Aspen PropertiesÒ are registered trademarks of
between these two simulation tools is mentioned in the previous Thermoflow LTD and Aspen Technology, Inc., respectively.
J. Hong et al. / Energy 35 (2010) 5391e5399 5393
Fig. 1. Overall process layout for the pressurized oxy-fuel system (modified from Ref. [10]).
The inlet and outlet temperatures of each heat exchanger: section. Under these cold stream temperature constraints,
TH,in ¼ the inlet temperature of the flue gas stream; increasing the dew point enables the latent enthalpy recovery at
TH,out ¼ the outlet temperature of the flue gas stream; higher temperatures. Consequently, we can recover more latent
TC,in ¼ the inlet temperature of the feedwater stream enthalpy from the flue gases at higher temperatures with
increasing the operating pressure. Fig. 2 shows the dependence of
To calculate DPHRSG, the following three equations [29e31] are the saturation temperature of the water (the blue line) and the
used to evaluate the Nusselt number,NuD ; the number of transfer available latent enthalpy (the red line) on the flue gas pressure. As
units, Ntu; and the number of tube rows, N, mentioned before, the available latent enthalpy is defined as the
recoverable amount of the latent enthalpy of the water in the flue
hD
NuD ¼ gases (hot stream) based on the inlet and outlet temperatures of
k 8 9
" the feedwater (cold stream) across the acid condenser.
1=2 #=
2D <
1=2
0:62ReD Pr1=3 ReD The available latent enthalpy increases with the operating
¼ 1þ 0:3þ !2=3 #1=4 1þ 282;000
3SL : ; pressure and is saturated above 10 bars, as shown in Fig. 2. This is
0:4
½1þ because we recover almost all HHV of the fuel as we increase the
Pr combustor operating pressure. As shown in Fig. 3, the fraction of
(3) the water whose latent enthalpy is recovered through the acid
condenser rises with the operating pressure. Above 10 bars, we
where, h ¼ heat transfer coefficient, k ¼ thermal conductivity. reach nearly 100% latent enthalpy recovery rate.
1=2 E 1 Because of a large amount of water in the oxy-fuel combustion
Ntu ¼ 1 þ R2 ln (4) flue gases, 48% (molar) in our base case, the increase in the satu-
Eþ1 ration temperature of the water enables the recovery of a signifi-
cant amount of the available latent enthalpy from the flue gases.
where, 3 ¼ Q_ =Q_ max ¼ m _ H cP;H ðTH;in TH;out Þ=Cmin ðTH;in TC;in Þ ¼
As shown in Fig. 4, the total thermal energy (the blue line) recov-
_
mC cP;C ðTC;out TC;in Þ=Cmin ðTH;in TC;in Þ, E ¼ ½2ðF RÞ=ðF 1Þ
ered from the flue gases increases by nearly 6%, as the combustor
ð1 þ RÞ=ð1 þ R2 Þ1=2 ; F ¼ ð3R 1=3 1Þ1=n , R ¼ Cmin =Cmax ; operating pressure is raised from 1.238 bars to 30 bars.
_ _
Cmin ¼ minfmH cP;H ; mC cP;C g; Cmax ¼ max fm _ H cP;H ; m
_ C cP;C g. The considerable increase in the thermal energy recovery lowers
the regeneration heat duty from the turbines. While the conven-
Ntu Cmin ST N C S tional atmospheric oxy-fuel system cannot recover the HHV of fuel
N¼ ¼ 8 tu min T 9
hc pDAc >
< S >
= through the steam generation unit, the pressurized oxy-fuel power
_H ST =2 cycle is able to recuperate most of the HHV of the fuel because of the
hc pDr m max T
; h i
0 Vmax >
:ST D S2 þ ST 2 1=2 >
D;
increased dew point as discussed above. As a result, the former
L 2 needs a higher portion of the steam from steam turbines. As we
(5) recover more thermal energy from the flue gases, the regeneration
heat duty and the corresponding steam bleeding from the low
The number of tube rows N is calculated by combining Eqs. (3)e(5).
pressure and the intermediate pressure steam turbines decrease.
Adding (1a) and (1b), we estimate the overall pressure drops
Fig. 4 shows the variation in the overall steam bleeding (the red
across the HRSG and the recirculation pipe. The result is shown in
line) with increase in the combustor operating pressure.
Section 3.3.2
As shown in Fig. 5, the gross power output increases with
increasing the operating pressure, following the thermal energy
3. Pressure dependence of the system performance recovery curve in Fig. 4.
2
Ntu does not change significantly with the operating pressure because the inlet
and outlet temperatures of the HRSG are fixed and the specific heat capacity of the
streams remains nearly constant as the pressure increases. However, as the cross- Fig. 2. Saturation temperature of the steam (the blue line) and the available latent
sectional area (the width) of the HRSG decreases, the number of tube rows enthalpy (the red line). (For interpretation of the references to colour in this figure
N needed to achieve the required heat transfer surface area becomes larger. legend, the reader is referred to the web version of this article.)
J. Hong et al. / Energy 35 (2010) 5391e5399 5395
Fig. 4. The variation in the thermal energy recovery (the blue line) and the overall
steam bleeding to feedwater heaters (the red line). (For interpretation of the references Fig. 6. (a) Deaerator feedwater inlet temperature and (b) acid condenser pinch point
to colour in this figure legend, the reader is referred to the web version of this article.) temperature.
5396 J. Hong et al. / Energy 35 (2010) 5391e5399
Table 2
Reference flue gas velocities within the flue gas recirculation pipe.
pipe pressure drop varies, as shown in Fig. 8(a). This variation leads
to the pressure ratio across the flue gas recirculation pipe, as shown
in Fig. 9(a). Combining the pressure ratios across the HRSG and the
recirculation pipe, we have the overall pressure ratio across the fan,
as shown in Fig. 9(b).
Because the fan compression work is a strong function of the
pressure ratio, it follows the variation in the pressure ratio over the
Fig. 7. Deaerator feedwater inlet mass flow rate.
fan and has the minimum value at 10 bars, as shown in Fig. 10.
3
Given the constant mass flow rate of the flue gases, the volumetric flow rate is
governed by the operating pressure or density. If we hold the diameter of the flue
gas recirculation pipe constant at: (a) the diameter at low P: the flue gas velocity
reaches the order of 1 m/s at high pressures, and it is not appropriate to operate at
this low velocity. (b) The diameter at high P: the flue gas velocity increases
significantly as the operating pressure is lowered to 1.238 bars. The magnitude
of this high velocity is not reasonable. To avoid these extreme cases and operate Fig. 8. (a) The HRSG pressure drop (the blue line) and the flue gas recirculation pipe
the flue gas recirculation system at a reasonable flue gas velocity, we changed pressure drop (the red line), (b) the overall pressure drop. (For interpretation of the
the diameter of the flue gas recirculation pipe, maintaining it within references to colour in this figure legend, the reader is referred to the web version of
a reasonable range. this article.)
J. Hong et al. / Energy 35 (2010) 5391e5399 5397
Fig. 11. Compression work demand of the ASU and the CPU.
Based on the results in Sections 3.3 and 3.4, we now define the
pressure dependence of the overall compression work demand in
the pressurized oxy-fuel system. Fig. 12 shows the variation in the
overall compression work as the operating pressure increases. The
total parasitic power demand follows the trend of the fan
compression work shown in Fig. 10. When the ASU compression
work is combined with that of the CPU, their sum does not vary
Fig. 9. (a) The pressure ratio across the HRSG (the blue line) and the pressure ratio much with the operating pressure. As a result, the overall
across the flue gas recirculation pipe (the red line), (b) the pressure ratio across the fan. compression work which includes the power consumptions of the
(For interpretation of the references to colour in this figure legend, the reader is ASU, the CPU and the recirculation fan is mostly dependent on the
referred to the web version of this article.) fan compression work. We conclude that the overall parasitic
However, the larger oxygen compression work required to power demand of the pressurized oxy-fuel system is a strong
operate the combustor at higher pressures is partially offset by function of the flue gas recirculation power requirement. Again, the
eliminating the oxygen pre-heater from the oxygen compression total parasitic power demand has the minimum at 10 bars as the
line. In conventional atmospheric combustion systems, the gaseous fan compression work does.
oxygen is pre-heated by utilizing high temperature thermal energy The variation in the overall parasitic work demand points out
sources such as steam or flue gases. The oxygen pre-heating steps that, in order to improve the performance of the pressurized oxy-
result in thermal energy penalties and lower the overall efficiency. fuel system, we should focus on the pressure drop within the flue
In contrast, the pressurized oxy-fuel power cycle reduces or elim- gas recirculation path.
inates the thermal duty of oxygen pre-heating while using oxygen
compression. 3.6. Net efficiency
On the other hand, because the flue gases are already at high
pressures, the compression work in the CPU decreases as the oper- The pressure sensitivity analysis provides the optimal pres-
ating pressure increases. The CPU compresses the CO2-concentrated sure, as shown in Fig. 13. Based on the parasitic power
Fig. 10. Fan compression work demand. Fig. 12. Overall parasitic compression work demand.
5398 J. Hong et al. / Energy 35 (2010) 5391e5399
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