Reforming natural gas for CO2 pre-combustion capture in combined cycle power plant

The aim of this study is to assess the conversion of a natural gas combined cycle power plant (NGCC) using an advanced gas turbine (GE9H) for CO₂ pre-combustion capture. The natural gas is reformed in an auto-thermal reformer (ATR) either with pure oxygen or with air. After water-shift conversion of CO into CO₂ and physical CO₂ recovery, the synthesis gas contains a high fraction of H₂. It is diluted with N₂ and steam to lower its low heating value (LHV) for NO _X emission control. Oxygen purity and reforming pressure have little impact on the performances. High-pressure reforming is preferred to reduce the process size. Air reforming results in a slightly higher efficiency but in a bigger process too. The CO₂ recovery rate has a big impact on the power plant efficiency since a lot of steam is required to lower the heating value (LHV) of the synthesis gas leaving the recovery process. Two values of LHV have been assessed. Steam consumption for natural gas reforming and synthesis gas dilution are the main consuming elements. An erratum to this article can be found at     

Decomposition characteristics of carbon dioxide by gas tunnel-type plasma jet

The increase of warm-room gas is thought to cause the rise of atmosphere temperature, which is called the warm-room effect. Therefore, the decomposition treatment of carbon dioxide (CO₂) gas is an important research subject in order to solve the global environmental problem. In this study, a high-energy plasma process was used to decompose CO₂ gas as a warm-room gas, and the decomposition mechanism was clarified by varying the plasma operation conditions. The possibility of transforming of the CO₂ gas to various resources was also discussed. Firstly, the performance test of the gas tunnel-type plasma jet used for decomposition of CO₂ was conducted, and decomposition characteristics of CO₂ gas by the gas tunnel-type plasma jet was determined under various conditions. The decomposition ratio of CO₂ was about 30%, when the power input was P=8 kW, and the CO₂ content in argon was 10%. Secondly, the improvement of operating conditions of the plasma jet was discussed in order to enhance its performance.     

A life cycle assessment of biomass cofiring in a coal-fired power plant

The generation of electricity, and the consumption of energy in general, often result in adverse effects on the environment. Coal-fired power plants generate over half of the electricity used in the U.S., and therefore play a significant role in any discussion of energy and the environment. By cofiring biomass, currently operating coal plants have an opportunity to reduce the impact they have, but to what degree, and with what trade-offs? A life cycle assessment has been conducted on a coal-fired power system that cofires wood residue. The assessment was conducted in a cradle-to-grave manner to cover all processes necessary for the operation of the power plant, including raw material extraction, feed preparation, transportation, and waste disposal and recycling. Cofiring was found to significantly reduce the environmental footprint of the average coal-fired power plant. At rates of 5% and 15% by heat input, cofiring reduces greenhouse gas emissions on a CO₂-equivalent basis by 5.4% and 18.2%, respectively. Emissions of SO₂, NO _x , non-methane hydrocarbons, particulates, and carbon monoxide are also reduced with cofiring. Additionally, total system energy consumption is lowered by 3.5% and 12.4% for the 5% and 15% cofiring cases, respectively. Finally, resource consumption and solid waste generation were found to be much less for systems that cofire. Electronic Publication     

Multi-objective optimization of steam power plants for sustainable generation of electricity

A unified framework that combines process simulation and multi-objective optimization is presented to simultaneously maximize the annual profit, while minimizing environmental impact (i.e., greenhouse gas emissions) of steam power plants with fixed flowsheet structures. The proposed methodology includes the selection of suitable primary energy sources (i.e., fossil fuels, biomass, biofuels, and solar energy) for sustainable electricity generation. For solving the problem of optimal selection of energy sources, a linear model is developed and included within a highly nonlinear simulation model for the parameter optimization of steam power plants that is solved by using genetic algorithms. This approach is robust and avoids making discrete decisions. Life cycle assessment technique is used to quantify the greenhouse gas emissions resulting from different combinations of energy sources and operating conditions of the power plants. The thermodynamic properties for liquid water and steam are calculated rigorously using the IAPWS-IF 97 formulation. An example problem of an advanced regenerative-reheat steam power plant is presented to illustrate the proposed method, which provides the Pareto optimal solutions, the types and amounts of primary energy sources as well as the optimal values of the operating conditions of the plant that simultaneously maximize the profit while minimizing environmental impact.     

Energie- und CO2-Bilanzen von Solarkollektoranlagen

Energy systems based on solar collectors or other renewable energy sources are normally regarded as CO₂ zero-emission systems because nearly no fossil fuels are used to operate the systems. But the complete evaluation of an energy system concerning its CO₂ reduction potential must not be restricted to the emissions during the operation of the system. The cumulative energy demand and the cumulative CO₂ emissions during the life cycle have to be considered. In case of a solar collector system, in particular the production-determined emissions and emissions due to the requirement of auxiliary electric power for the collector pump are important. An energy analysis is this kind was performed for solar domestic hot water systems. It is shown that the consideration of the life cycle emissions reduces significantly the CO₂ reduction potential of solar collector systems whereby the design of the system has a major influence.     

Availability analysis of integrated gasification combined cycle power plants with backup fuel and NOx reduction

Backup fuel can be utilised to improve the effectiveness (energy availability) of an integrated gasification combined cycle power plant. The gas turbine can be operated independently, also, with a backup fuel. By independent operation, the selective catalytic reduction (SCR), which is installed in the heat recovery steam generator for lower NO_x, emission is bypassed and a relatively high level of NO_x is emitted. Improving the effectiveness of a power plant by using backup fuel involves increased cost for backup fuel and higher NO_x emission.The object of this paper is to improve the effectiveness of a power plant with a minimum of backup fuel and NO_x emissions.The study shows how the application of appropriate reserve capacity (active redundancy) and a suitable repair policy can minimize the use of backup fuel and NO_x emissions, and, at the same time, improve the effectiveness of integrated gasification combined cycle power plants.     

Performance improvement of a transcritical CO2 refrigeration cycle using two-stage thermoelectric modules in sub-cooler and gas cooler

A novel integration of a trans-critical CO₂ refrigeration cycle with thermoelectric modules in the gas cooler and sub-cooler is presented, wherein a two-stage thermoelectric generator (TEG) produces power from the waste heat of gas cooler, which is a considerable amount of required power in two-stage thermoelectric cooler (TEC) to sub-cool the refrigerant before expansion device. Mathematical simulation of TEG and TEC as well as energy and exergy based thermodynamic analysis of the proposed system is performed, and the effects of some important parameters on the system performance are investigated. A comparison is carried out between the proposed system and the simple CO₂ refrigeration cycle, indicating that the proposed configuration improves the coefficient of performance (COP) about 19%. Also, it is observed that the TEC and TEG have better performance in a two-stage configuration. The parametric study reveals that the new configuration decreases the cycle operation pressure at maximum COP and exergetic efficiency.     

A systematic technique for cost-effective CO<Subscript>2</Subscript> emission reduction in process plants

There has been growing interests to reduce the environmental impact caused by greenhouse gas emissions from process plants through various energy conservation strategies. CO₂ emissions are closely linked to energy generation, conversion, transmission and utilisation. Various studies on the design of energy-efficient processes, optimal mix of renewable energy and hybrid power system are driven to reduce reliance on fossil fuel as well as CO₂ emissions reduction. This paper presents a systematic technique in the form of graphical visualisation tool for cost-effective CO₂ emission reduction strategies in industry. The methodology is performed in four steps. The first step involves calculating the energy consumption of a process plant. This is followed by identification of potential strategies to reduce CO₂ emissions using the CO₂ management hierarchy as a guide. In the third step, the development of “Investment” versus “CO₂ Reduction” (ICO₂) plot is constructed to measure the optimal CO₂ emission reductions achieved from the implementation of possible CO₂ reduction strategies. The Systematic Hierarchical Approach for Resilient Process Screening (Wan Alwi and Manan in AIChE J 11:3981–3988, 2006) method is used in the fourth step via substitution or partial implementation of the various CO₂ reduction options in order to meet the cost-effective emission reduction within the desired investment limit or payback period (PP). An illustrative case study on a palm oil refinery plant has been used to demonstrate the implementation of the method in reduction of CO₂ emissions. The developed graphical tool provides an insight-based approach for systematic CO₂ emission reduction in the palm oil refinery considering both heat and power energy sources. Result shows that 31.2 % reduction in CO₂ emissions can be achieved with an investment of USD 38,212 and PP of 10 months based on the present energy prices in Malaysia.     

Hydrogen for oil refining via biomass indirect steam gasification: energy and environmental targets

The energy and CO₂ consequences of substitution of a fossil-fuel-based hydrogen production unit with a biomass-based process in a large European refinery are studied in this study. In the base case, the biomass-based process consists in atmospheric, steam–blown indirect gasification of air-dried woody biomass followed by necessary upgrading steps. The effect of gradually substituting the current refinery hydrogen production unit with this process on global energy and CO₂ targets is estimated first. Few process concepts are studied in further detail by looking at different degrees of heat integration with the remaining refinery units and possible polygeneration opportunities. The proposed process concepts are compared in terms of energy and exergy performances and potential reduction in refinery CO₂ emission also taking into account the effect of marginal electricity. Compared to the base case, an increase by up to 8 % points in energy efficiency and 9 % points in exergy efficiency can be obtained by exploiting process integration opportunities. According to energy efficiency, steam production appears the best way to use excess heat available in the process while electricity generation through a heat recovery steam cycle appears the best option according to exergy efficiency results. All investigated cases yield to significant reduction in CO₂ emissions at the refinery. It appears in particular that maximal emission reduction is obtained by producing extra steam to cover the demand of other refinery units if high efficiency marginal electricity scenarios are considered.     

Life cycle assessment of membrane-based carbon capture and storage

Many investigations have conducted life cycle assessments (LCA) of the most commonly discussed routes of carbon capture and storage (CCS): post-combustion with amine wash separation; oxyfuel using cryogenic air separation and pre-combustion by integrated gasification combined cycle (IGCC) using physical separation. A research alliance developed corresponding separation systems using different types of membranes to allow a more energy efficient separation process: polyactive polymeric membranes for post-combustion, ceramic membranes for oxyfuel and metallic membranes for IGCC separation. By conducting an LCA, the study examines the actual greenhouse gas emissions and other environmental impacts of the new membrane separation technologies, together with concepts implementing the more common technologies. The reference systems represent today’s state-of-the-art supercritical coal fired power plant in Germany, together with a more advanced ultra-supercritical plant operating at 700 °C without CO₂ capture. The results demonstrate that among the three reference power plants the IGCC is the superior concept due to the highest efficiency. Regarding climate change, the IGCC power plants with CO₂ capture are still the best concepts. When other environmental impacts are considered, the capture technologies are inferior. The membrane concepts show the overall better results in comparison to the conventional capture technologies. The environmental impacts for membrane applications add a new range of findings to the field of CCS LCAs. Now the results for several different approaches can be compared directly for the first time.     

Methodology for implementing power plant efficiency standards for power generation: potential emission reduction

Some methods of generating power such as power generation through coal, natural gas, oil result in inevitable emissions of greenhouse gases. While power generation is necessary due to its increasing demand, it is important for power companies to generate their power in an efficient manner to reduce its effect on the environment. One of the most effective ways of tackling inefficiency issues is through the implementation of efficiency standard. While there exist a lot of studies addressing the topic of energy efficiency standards, there are very few papers that deal specifically with efficiency standard for power generation plant. This paper presents methodology for the implementation of power plant efficiency standard; as mandatory or voluntary regulatory instrument, that may be implemented by the government to control greenhouse emissions from power plants. It is hoped that through its implementation, power companies shall become more conscious of their efficiency and emission quality, hereby encouraging the adoption of more efficient energy sources and latest available technologies. In this paper, methods of calculating greenhouse intensity value and its corresponding allowable ranges have been demonstrated. Case study on a 10-year-old base-load multi-fuel-fired power plant in Malaysia has shown that the power plant is in conformance to the power plant efficiency standard, with an actual greenhouse intensity of 859.4461 kgCO₂/MWh sent-out, well within the allowable range of greenhouse intensities for that power plant which is between 760 and 890 kgCO₂/MWh sent-out. It has also been demonstrated that older power plants are allowed to have higher values of greenhouse intensity. Benefits of utilising natural gas and operating the power plant at full load have also been shown.

     

Exergy recuperative CO2 gas separation in pre-combustion capture

The integrated coal gasification combined cycle (IGCC) can achieve higher power generation efficiency than conventional pulverized coal combustion power plants. However, a CO₂ capture process prevents improving power generation efficiency of IGCC, because CO₂ separation from gas mixtures requires huge amounts of energy. Therefore, in this study, we analyzed the CO₂ separation process in the pre-combustion capture process using a process simulator (PRO/II) in the steady state, and proposed a new process using a modularity based on self-heat recuperation (SHR) technology to decrease energy consumption. Pre-combustion capture was applied in the IGCC plant, which involved coal gasification and CO-shift conversion with CO₂ capture. The results show that the energy consumption for the CO₂ separation process using SHR was decreased by two-thirds. This means that the power generation efficiency can be improved by SHR compared with conventional IGCC with a CO₂ capture process.     

Experimental evaluation of a CO2 transcritical refrigeration plant with dedicated mechanical subcooling

CO₂ transcritical refrigeration cycles require optimization to reach the performance of conventional solutions at high ambient temperatures. Theoretical studies demonstrated that the combination of a transcritical cycle with a mechanical subcooling cycle improves its performance; however, any experimentation with CO₂ has been found. This work presents the energy improvements of the use of a mechanical subcooling cycle in combination with a CO₂ transcritical refrigeration plant, experimentally. It tested the combination of a R1234yf single-stage refrigeration cycle with a semihermetic compressor for the mechanical subcooling cycle, with a single-stage CO₂ transcritical refrigeration plant with a semihermetic compressor. The combination is evaluated at two evaporating levels of the CO₂ cycle (0 and −10 °C) and three heat rejection temperatures (24, 30 and 40 °C). The optimum operating conditions and capacity and COP improvements are analysed with maximum increments on capacity of 55.7% and 30.3% on COP.     

Steel mill slags energy potential: the case of the steel factory of Arcelor-Mittal in Asturias (Spain)

Slag accounts for most of the residuals or by-products of the steel manufacturing process and represents a not inconsiderable amount of energy waste and CO₂ emissions. Energy recovery from steel mill slags is not actually performed because of the difficulty of the industrial implementation, but the actual demand and the incentives for new electricity generation plants based on renewable energies and on industrial waste heat recovery offer a new opportunity to evaluate the feasibility of this process. This article presents a review of the slag energy potential on a global scale, and a proposal for a recovery plant in the factories of Arcelor-Mittal in Asturias (Spain), based on a steam Rankine cycle for electricity production in a turbine. The plant production and viability have been analyzed using the typical technical and economic values for this kind of plant. Also, a parametric study has been performed on the heat recuperator efficiency and investment rate.     

Comparitive analysis of an automotive air conditioning systems operating with CO2 and R134a

This paper evaluates performance merits of CO₂ and R134a automotive air conditioning systems using semi-theoretical cycle models. The R134a system had a current-production configuration, which consisted of a compressor, condenser, expansion device, and evaporator. The CO₂ system was additionally equipped with a liquid-line/suction-line heat exchanger. Using these two systems, an effort was made to derive an equitable comparison of performance; the components in both systems were equivalent and differences in thermodynamic and transport properties were accounted for in the simulations. The analysis showed R134a having a better COP than CO₂ with the COP disparity being dependent on compressor speed (system capacity) and ambient temperature. For a compressor speed of 1000 RPM, the COP of CO₂ was lower by 21% at 32.2°C and by 34% at 48.9°C. At higher speeds and ambient temperatures, the COP disparity was even greater. The entropy generation calculations indicated that the large entropy generation in the gas cooler was the primary cause for the lower performance of CO₂.     

Comparative life cycle assessment of beneficial applications for scrap tires

Life cycle assessment is used to determine the most environmentally beneficial alternatives for reuse of scrap tires, based on the concept of industrial ecology. Unutilized scrap tires can be a major source of pollution, and in the past decade Federal and state governments in the United States have encouraged the recycling and reuse of scrap tires in a number of applications, ranging from energy recovery to civil engineering materials to utilization of ground rubber in manufacturing. Life cycle inventory data are collected from primary industry sources as well as published literature, and life cycle impact analysis is performed using the TRACI tool. The results indicate that beneficial reuse of scrap tires, particularly in cement plants and artificial turf, provides reductions in greenhouse gas (GHG) emissions, air toxics, and water consumption. For example, every metric ton of tire-derived fuel substituted for coal in cement kilns avoids an estimated 543 kg (CO₂ equivalent) of direct and indirect GHG emissions. Taking into account the deductible CO₂ from natural rubber, the avoided GHG emissions would be 613 CO₂ kg eq. per metric ton. The use of scrap tires for fuel in cement plants provides more reductions in most environmental impact categories compared to other scrap tire applications, excluding application in artificial turf. Although the use of ground rubber for artificial turf offers the greatest environmental emission reductions, it has limited potential for large-scale utilization due to the saturated market for artificial turf. Therefore, the use of fuel derived from scrap tires in cement production appears to be an attractive option in view of its large market capacity and significant potential for environmental impact reductions.     

Design-theoretical study of cascade CO2 sub-critical mechanical compression/butane ejector cooling cycle

In this paper an innovative micro-trigeneration system composed of a cogeneration system and a cascade refrigeration cycle is proposed. The cogeneration system is a combined heat and power system for electricity generation and heat production. The cascade refrigeration cycle is the combination of a CO₂ mechanical compression refrigerating machine (MCRM), powered by generated electricity, and an ejector cooling machine (ECM), driven by waste heat and using refrigerant R600. Effect of the cycle operating conditions on ejector and ejector cycle performances is studied. Optimal geometry of the ejector and performance characteristics of ECM are determined at wide range of the operating conditions. The paper also describes a theoretical analysis of the CO₂ sub-critical cycle and shows the effect of the MCRM evaporating temperature on the cascade system performance. The obtained data provide necessary information to design a small-scale cascade system with cooling capacity of 10 kW for application in micro-trigeneration systems.     

Transcritical CO2 refrigeration cycle with ejector-expansion device

An ejector expansion transcritical CO₂ refrigeration cycle is proposed to improve the COP of the basic transcritical CO₂ cycle by reducing the expansion process losses. A constant pressure mixing model for the ejector was established to perform the thermodynamic analysis of the ejector expansion transcritical CO₂ cycle. The effect of the entrainment ratio and the pressure drop in the receiving section of the ejector on the relative performance of the ejector expansion transcritical CO₂ cycle was investigated for typical air conditioning operation conditions. The effect of different operating conditions on the relative performance of the ejector expansion transcritical CO₂ cycle was also investigated using assumed values for the entrainment ratio and pressure drop in the receiving section of the ejector. It was found that the COP of the ejector expansion transcritical CO₂ cycle can be improved by more than 16% over the basic transcritical CO₂ cycle for typical air conditioning operation conditions.     

Low-temperature CO2 capture technologies – Applications and potential

CO₂ capture by chemical or physical sorption and membrane separation have been the dominant fields of research within post- and pre-combustion CO₂ capture from power cycles and industrial processes. Except for oxy-combustion capture applications, limited attention has been given to low-temperature capture from flue gas and synthesis gas by phase separation. This paper gives an overview of common CO₂ capture conditions for a broad range of different power cycles and industrial processes. For a selected range of capture conditions, potential applications for low-temperature CO₂ capture have been evaluated with respect to energy consumption and CO₂ capture ratio. For all applications of low-temperature capture, specific power consumption and obtainable CO₂ capture ratio are sensitive to flue-gas or synthesis-gas feed CO₂ concentration. However, for certain applications such as synthesis gas from coal gasification, low-temperature capture shows promising potential and highly competitive energy figures compared to baseline technology.     

Performance evaluation of a two-stage CO2 cycle with gas injection in the cooling mode operation

The cooling performance and reliability of a transcritical CO₂ cycle can be significantly improved by using a multi-stage compressor with gas injection because the CO₂ cycle has a large pressure difference across a compressor. The objective of this study is to investigate the performance and operating characteristics of a two-stage CO₂ cycle with gas injection. In this study, the performances of a two-stage CO₂ cycle with gas injection (called as “two-stage gas injection cycle”) were measured as the amount of refrigerant charge, first- and second-stage compressor frequencies, and first- and second-stage EEV openings were varied in the cooling mode operation. The cooling COP of the two-stage gas injection cycle was maximally enhanced by 16.5% over that of the two-stage non-injection cycle in the experiments. In addition, when the first- and second-stage EEV openings were increased, the compression ratio decreased and this in turn, improved the cooling COP of the two-stage gas injection cycle. However, when the first-stage EEV opening was increased, the mass flow rate through the evaporator decreased, and this in turn, decreased the cooling capacity of the two-stage gas injection cycle. Therefore, in the two-stage gas injection cycle, an optimum control of both EEV openings is required.