technology advances in post- combustion capture to
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Technology Advances in Post-Combustion Capture to Approach a
Viable Business case
Prachi Singh, John Davison IEA Greenhouse Gas R&D Programme, UK
& Luca Mancuso, Noemi Ferrari
Foster Wheeler, Italy
Scope of the project
Perform technical and economical assessment of Newly build Coal fired Power Plants with the leading CO2 capture technology (Location: The Netherlands)
Currently this work is in progress
Following cases will be presented Supercritical Pulverized Coal (SCPC) SCPC + CO2 Capture
SCPC + Biomass co-firing + CO2 Capture
Sensitivity Analysis: Cooling System Sea water & Air cooling SCPC SCPC + CO2 Capture
SCPC without CO2 Capture
Fuel flow rate 325t/h
Thermal input LHV 2335MWth
Main steam condition
270bar(a) /600 C
Reheat steam condition
60bar(a) /620 C
Gross output 1076.7MWe
Net output 1032.7MWe
Gross efficiency LHV 46.1%
Net efficiency LHV 44.1%
Fuel consumption 2.27MWth /MWe
Specific CO2 emission
741.8 kg/MWh
Flue Gas Treatment
Alstom Wet Flue Gas Desulphurization (WFGD) SO2 10ppmv*, SO3 13ppmv*
(CO2 Capture Case)
Selective Catalytic Reduction (SCR)
NOx <130mg/Nm3* (CO2 Capture Case)
*(6% dry O2)
CO2 Capture Technology Amine based solvent CO2 Absorption process
Several companies are offering CO2 capture technology:
• Aker Clean Carbon: Amine based solvent process • Alstom: Ammonia based process (CAP) • CANSOLV: Amine based solvent; Combined SO2/CO2 removal • CB&I: MEA based scrubbing technology • FLUOR: Econamine FG Plus process • HTC Energy: Purenergy CCS Capture SystemTM, amine based • Mitsubishi Heavy Industries (MHI): KS-1 process, based on a
formulation of sterically hindered amines • SIEMENS: Amino acid salt solution based process
Some of the above-listed suppliers were asked to support the study; amongst them, CANSOLV has provided specific data for this study
Cansolv CO2 Capture Process 90% CO2 removal
2×50% Train
•Absorber Intercooling •Lean Flash Mechanical Vapor recompression
CO2~ 14 vol% NO2 ~1ppmv SO2 ~1 ppmv 122 C
37 C
SCPC with CO2 Capture: Steam Integration
Steam Extraction
Condensate preheated at stripper overhead condenser and compressor intercoolers
SCPC with CO2 Capture: Biomass Co-firing
Co-fire biomass to meet net zero CO2 emission (7.5%)
Modification of coal burner for biomass
injection lance
Slight increase in flue gas flow rate and CO2
concentration
CO2 Compression and Dehydration
Two parallel trains, including compressor, separation drums, coolers, dehydration system and final pump
• Four stage centrifugal compressor, electrically driven, includes anti-surge control, vent, inter-coolers, knockout drums and condensate draining facilities as appropriate
• At each compression stage outlet, part of the heat is recovered to pre-heat the condensate from the steam cycle
CO2 from the third compression stage is routed to the dehydration unit (consist of two bed), via a solid desiccant, (e.g. Activated Alumina and Molecular Sieves)
Finally CO2 is delivered at 110 bar, Dense phase to pipeline for transportation
Water Consumption
Cooling water system is based on Natural Draft Cooling Tower
SCPC+CO2
Electricity Consumption
CO2 capture and compression energy consumption is 62%
Plant Performance
Overall Plant performance Unit SCPC SCPC+
CO2 SCPC+
Bio+ CO2
Coal flow rate t/h 325.0 325.0 300.6
Biomass flow rate t/h - - 86.4
Fuel LHV kJ/kg 25870 25870 21725
Thermal Energy of Feedstock (LHV) MWth 2335 2335 2335
Gross Electric Power Output MWe 1076.7 958.1 948.8
Net Electric Power Output MWe 1032.7 824.9 811.0
Gross Electrical Efficiency (LHV) % 46.1% 41.0% 40.6%
Net Electrical Efficiency ( LHV) % 44.1% 35.2% 34.6% Efficiency Reduction compared to SCPC
% - 8.9% 9.5%
Net CO2 emission per net power production
kg/MWh 741.8 91.0 0.0
Environmental Impact
Gaseous Emission SCPC SCPC+ CO2 SCPC+ Bio+ CO2
Wet gas flow rate, kg/h 3,740,000 2,977,000 3,030,000 Flow, Nm3/h (1) 2,857,000 2,410,000 2,445,000 Temperature, °C 90 95 95 Composition (% vol) (% vol) (% vol)
Ar 0.85 1 1 N2 71.4 84.66 84.38 O2 3.2 4.13 4.11
CO2 13.68 1.58 1.6 H2O 10.88 8.62 8.62
Emission mg/Nm3 (1) mg/Nm3 (1) mg/Nm3 (1) NOx < 150 < 50 mg/Nm3 (1) < 50 mg/Nm3 (1) SOx < 150 < 1 ppmv (1) < 1 ppmv (1)
Particulate < 10 < 10 mg/Nm3 (1) < 10 mg/Nm3 (1) (1) Dry gas, O2 content 6% vol.
Sensitivity Analysis: Cooling System
Sea water (SW) Once through seawater, directly pumped from sea to heat exchanger Air cooling (AC) Ambient air is used as cooling medium In SW & AC cases raw
water consumption is lower than Base case (Cooling tower)
Sensitivity Analysis: Cooling System
Operational Cost
• Fixed cost include Direct labour, Administrative/General overheads, Insurance & Local taxes, Maintenance;
• Chemical & Waste disposal include solvent • Coal 2.5 €/GJ (LHV)
Variable Cost
Total Plant Cost
SCPC Total Plant Cost: 1,490m€
SCPC + CO2 Total Plant Cost: 2,279m€
Levelised Cost of Electricity (LCOE)
Bituminous Coal: 2,5 €/GJ (LHV); Discount rate: 8% CO2 transport & storage: 10 €/t; 85% load factor; Constant €, 2013
Conclusions
Net Efficiency reduction for SCPC plant was found to be 8.9% points for CO2 capture case and for biomass and CO2 capture case 9.5% points
Impact of cooling system on plant Net Efficiency for sea water and air cooling is +/- 0.6% points for SCPC case and +/- 0.4% points for SCPC+CO2 case
15% increase in operation cost and 53% increase in capital cost for SCPC with CO2 capture plant
Levelised cost of electricity for SCPC with CO2 capture case was found to be 94.7€/MWh (52 €/MWh)
October 5th - 9th 2014 AUSTIN, TX – USA www.GHGT.info
•Call for papers 27th Sep. 2013 •Deadline for abstracts 10th Jan. 2014 •Registration opens 7th Mar. 2014 •Authors notified 2nd May 2014 •Early bird closes 13th June 2014
prachi.singh@ieaghg.org
Sensitivity Analysis: Cooling System
Overall Plant Performance
Unit SCPC SCPC-
SW SCPC-
AC SCPC +
CO2
SCPC-SW + CO2
SCPC-AC + CO2
Fuel flow rate t/h 325 325 325 325 325 325 Gross Electric Power output
MWe 1077 1091 1062 958 969 947
Net Electric Power output
MWe 1033 1048 1018 825 835 816
Gross Electrical Efficiency (LHV)
% 46.1% 46.7% 45.5% 41.0% 41.5% 40.6%
Net Electrical Efficiency (LHV)
% 44.1% 44.7% 43.5% 35.2% 35.6% 34.8%
Fuel Consumption per net power production
MWth/MWe 2.27 2.24 2.30 2.84 2.81 2.87
CO2 emission per net power production
kg/MWh 741.8 731.2 752.3 91.0 89.9 92.0
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