Cost and performance of fossil fuel power plants with CO2 capture and storage

CO₂ capture and storage (CCS) is receiving considerable attention as a potential greenhouse gas (GHG) mitigation option for fossil fuel power plants. Cost and performance estimates for CCS are critical factors in energy and policy analysis. CCS cost studies necessarily employ a host of technical and economic assumptions that can dramatically affect results. Thus, particular studies often are of limited value to analysts, researchers, and industry personnel seeking results for alternative cases. In this paper, we use a generalized modeling tool to estimate and compare the emissions, efficiency, resource requirements and current costs of fossil fuel power plants with CCS on a systematic basis. This plant-level analysis explores a broader range of key assumptions than found in recent studies we reviewed for three major plant types: pulverized coal (PC) plants, natural gas combined cycle (NGCC) plants, and integrated gasification combined cycle (IGCC) systems using coal. In particular, we examine the effects of recent increases in capital costs and natural gas prices, as well as effects of differential plant utilization rates, IGCC financing and operating assumptions, variations in plant size, and differences in fuel quality, including bituminous, sub-bituminous and lignite coals. Our results show higher power plant and CCS costs than prior studies as a consequence of recent escalations in capital and operating costs. The broader range of cases also reveals differences not previously reported in the relative costs of PC, NGCC and IGCC plants with and without CCS. While CCS can significantly reduce power plant emissions of CO₂ (typically by 85–90%), the impacts of CCS energy requirements on plant-level resource requirements and multi-media environmental emissions also are found to be significant, with increases of approximately 15–30% for current CCS systems. To characterize such impacts, an alternative definition of the “energy penalty” is proposed in lieu of the prevailing use of this term.     

The cost of integration of zero emission power plants—A case study for the island of Cyprus

In this work, a technical, economic and environmental analysis is carried out for the estimation of the optimal option scenario for the Cyprus's future power generation system. A range of power generation technologies integrated with carbon capture and storage (CCS) were examined as candidate options and compared with the business as usual scenario. Based on the input data and the assumptions made, the simulations indicated that the integrated gasification combined cycle (IGCC) technology with pre-combustion CCS integration is the least cost option for the future expansion of the power generation system. In particular, the results showed that for a natural gas price of 7.9US$/GJ the IGCC technology with pre-combustion CCS integration is the most economical choice, closely followed by the pulverized coal technology with post-combustion CCS integration. The combined cycle technology can, also, be considered as alternative competitive technology. The combined cycle technologies with pre- or post-combustion CCS integration yield more expensive electricity unit cost. In addition, a sensitivity analysis has been also carried out in order to examine the effect of the natural gas price on the optimum planning. For natural gas prices greater than 6.4US$/GJ the least cost option is the use of IGCC technology with CCS integration. It can be concluded that the Cyprus's power generation system can be shifted slowly towards the utilization of CCS technologies in favor of the existing steam power plants in order not only to lower the environmental emissions and fulfilling the recent European Union Energy Package requirements but also to reduce the associated electricity unit cost.     

Techno-economic assessment of fossil fuel power plants with CO2 capture – Results of EU H2-IGCC project

In order to address the ever-increasing demand for electricity, need for security of energy supply, and to stabilize global warming, the European Union co-funded the H₂-IGCC project, which aimed to develop and demonstrate technological solutions for future generation integrated gasification combined cycle (IGCC¹) plants with carbon capture. As a part of the main goal, this study evaluates the performance of the selected IGCC plant with CO₂ capture from a techno-economic perspective. In addition, a comparison of techno-economic performance between the IGCC plant and other dominant fossil-based power generation technologies, i.e. an advanced supercritical pulverized coal (SCPC²) and a natural gas combined cycle (NGCC³), have been performed and the results are presented and discussed here. Different plants are economically compared with each other using the cost of electricity and the cost of CO₂ avoided. Moreover, an economic sensitivity analysis of every plant considering the realistic variation of the most uncertain parameters is given.     

Performance and cost of wet and dry cooling systems for pulverized coal power plants with and without carbon capture and storage

Thermoelectric power plants require significant quantities of water, primarily for the purpose of cooling. Water also is becoming critically important for low-carbon power generation. To reduce greenhouse gas emissions from pulverized coal (PC) power plants, post-combustion carbon capture and storage (CCS) systems are receiving considerable attention. However, current CO₂ capture systems require a significant amount of cooling. This paper evaluates and quantifies the plant-level performance and cost of different cooling technologies for PC power plants with and without CO₂ capture. Included are recirculating systems with wet cooling towers and air-cooled condensers (ACCs) for dry cooling. We examine a range of key factors affecting cooling system performance, cost and plant water use, including the plant steam cycle design, coal type, carbon capture system design, and local ambient conditions. Options for reducing power plant water consumption also are presented.     

Study on different zero CO2 emission IGCC systems with CO2 capture by integrating OTM

In this paper, different zero CO₂ emission integrated gasification combined cycle (IGCC) systems based on the oxy‐fuel combustion method by integrating with oxygen ion transfer membrane (OTM) with and without sweep gas are proposed in order to reduce the energy consumption of CO₂ capture. By utilizing the Aspen Plus software, the overall system models are established. The performances of the proposed systems are compared with the traditional IGCC system without CO₂ capture and the zero CO₂ emission IGCC system based on the oxy‐fuel combustion method using the cryogenic air separation unit. In addition, the effects of OTM key parameters on the proposed system performance, such as the feed side pressure, permeate side pressure, and operating temperature, are investigated and analyzed. The results show that the efficiency of the zero CO₂ emission IGCC system based on the oxy‐fuel combustion method integrated with OTM without sweep gas is 6.67% lower than that of the traditional IGCC system without CO₂ capture, but 1.88% higher than that of the zero CO₂ emission IGCC system using the cryogenic air separation unit, and 0.64% lower than that of the proposed system with sweep gas. The research achievements will provide valuable references for further study on CO₂ capture based on IGCC with lower energy penalty. Copyright © 2016 John Wiley & Sons, Ltd.     

Performance evaluation of integrated gasification solid oxide fuel cell/gas turbine systems including carbon dioxide capture

In this study, system layouts for integrated gasification solid oxide fuel cell/gas turbine (IG-SOFC/GT) systems were proposed and their performance was comparatively evaluated. A baseline IGCC was simulated, and the calculation models were validated. Based on the IGCC system, two IG-SOFC/GT system layouts with different SOFC thermal management methods were established, and their performance was analyzed. The IG-SOFC/GT systems were found to produce much higher power and better efficiency than the IGCC. With regard to SOFC thermal management, the exit gas recirculation scheme showed better performance than the cathode heat exchange scheme. The impact of CO₂ capture was investigated in both the IGCC and IG-SOFC/GT systems, and the penalties in power output and efficiency due to pre-combustion CO₂ capture were found to be milder in the IG-SOFC/GT systems than in the IGCC. An IG-SOFC/GT system adopting oxy-combustion-based CO₂ capture was proposed, and its thermal efficiency was predicted to be sensibly higher than the system with pre-combustion CO₂ capture. Its net power output was predicted to be less than that of the system with pre-combustion technology, but was still much larger than that of the IGCC with pre-combustion CO₂ capture.     

Thermodynamic performance assessment and comparison of IGCC with solid cycling process for CO2 capture at high and medium temperatures

Solid sorbents can be used to capture CO₂ from pre-combustion sources at various temperatures. MgO and CaO are typical medium- and high-temperature CO₂ sorbents. However, pure MgO is not active toward CO₂. The addition of Na₂CO₃ increases the operating temperature and significantly increases the reactivity of sorbents to capture CO₂. Na₂CO₃-promoted MgO is a promising medium-temperature CO₂ sorbent. In this study, the thermodynamic performance of integrated gasification combined cycle (IGCC) systems with Na₂CO₃–MgO-based warm gas decarbonation (WGDC) and CaO-based hot gas decarbonation (HGDC) is evaluated and compared with that of an IGCC system with methyldiethanolamine (MDEA)-based cold gas decarbonation (CGDC). Assuming that the average CO₂ capture capacities of solid sorbents are one-third of their theoretical maxima, we reveal that the IGCC system undergoes approximately 2.8% and 3.6% improvement on net efficiency when switching from CGDC to WGDC and to HGDC, respectively. The net efficiency of the system is increased by improving the CO₂ capture capacity of the sorbent. The IGCC with Na₂CO₃–MgO experiences more significant increase in efficiency than that with CaO along with the improvement of sorbent average CO₂ capture capacity. The efficiency of the IGCC systems reaches the same value when the average CO₂ capture capacities of both sorbents are 53% of their theoretical levels. The effects of gas turbine combustor fuel gas inlet temperature on IGCC system performance are analyzed. Results show that the efficiency of the IGCC systems with HGDC and WGDC increases by 0.74% and 0.53% respectively as the fuel gas inlet temperature increases from 250 °C to 650 °C.     

Determinants of the costs of carbon capture and sequestration for expanding electricity generation capacity

This study models the costs of electricity generation with carbon capture and sequestration (CCS), from generation at the power plant to carbon injection at the reservoir, examining the economic factors that affect technology choice and CCS costs at the individual plant level. The results suggest that natural gas and coal prices have profound impacts on the carbon price needed to induce CCS. To extend previous analyses we develop a "cost region" graph that models technology choice as a function of carbon and fuel prices. Generally, the least-cost technology at low carbon prices is pulverized coal, while intermediate carbon prices favor natural gas technologies and high carbon prices favor coal gasification with capture. However, the specific carbon prices at which these transitions occur is largely determined by the price of natural gas. For instance, the CCS-justifying carbon price ranges from $27/t CO₂ at high natural gas prices to $54/t CO₂ at low natural gas prices. This result has important implications for potential climate change legislation. The capital costs of the generation and CO₂ capture plant are also highly important, while pipeline distance and criteria pollutant control are less significant.     

Life cycle GHG assessment of fossil fuel power plants with carbon capture and storage

The evaluation of life cycle greenhouse gas emissions from power generation with carbon capture and storage (CCS) is a critical factor in energy and policy analysis. The current paper examines life cycle emissions from three types of fossil-fuel-based power plants, namely supercritical pulverized coal (super-PC), natural gas combined cycle (NGCC) and integrated gasification combined cycle (IGCC), with and without CCS. Results show that, for a 90% CO₂ capture efficiency, life cycle GHG emissions are reduced by 75–84% depending on what technology is used. With GHG emissions less than 170 g/kWh, IGCC technology is found to be favorable to NGCC with CCS. Sensitivity analysis reveals that, for coal power plants, varying the CO₂ capture efficiency and the coal transport distance has a more pronounced effect on life cycle GHG emissions than changing the length of CO₂ transport pipeline. Finally, it is concluded from the current study that while the global warming potential is reduced when MEA-based CO₂ capture is employed, the increase in other air pollutants such as NO_x and NH₃ leads to higher eutrophication and acidification potentials.     

Clean coal technology development in China

Coal is found in huge amounts throughout the world and is expected to play a crucial role as an abundant energy source. However, one critical issue in promoting coal utilization is controlling environmental pollution. Clean coal technologies are needed to utilize coal in an environmentally acceptable way and to improve coal utilization efficiency. This paper describes coal's role in China's energy system and the environmental issues related to coal use. Coal is responsible for 90% of the SO₂ emissions, 70% of the dust emissions, 67% of the NO_x emissions, and 70% of the CO₂ emissions. But as the most abundant energy resource, it will continue to be the dominant energy supply for a long time. Therefore, the development and deployment of clean coal technologies are crucial to promote sustainable development in China. Clean coal technologies currently being developed in China are described including high efficiency combustion and advanced power generation technologies, coal transformation technologies, IGCC (integrated gasification combined cycle) and carbon capture and storage (CCS). Although China only recently began developing clean coal technologies, there have been many successes. Most recent orders of coal-fired power plants are units larger than 600 MW and new orders for supercritical and ultra supercritical systems are increasing rapidly. Many national research programs, industrial research programs and international collaboration projects have been launched to develop on IGCC and CCS systems in China. Finally, suggestions are given on how to further promote clean coal technologies in China.     

Assessment of oxyfuel power generation technologies

In this work, a cost–benefit analysis concerning the use of oxyfuel combustion technology is carried out. For the analysis, the IPP optimization software is used in which a decouple optimization method for power technology selection in competitive markets is employed and the electricity unit cost and the CO₂ avoidance cost are calculated. The results indicate that oxyfuel technology is a competitive CO₂ capture and storage (CCS) technology. In addition, the effect of varying loan interest rates was investigated in the economic performance of an oxyfuel combustion plant. This analysis, revealed that up to a value of loan interest of approximately 5.3% the oxyfuel plant retains the competitive electricity unit costs (compared to other CCS technologies). For higher interest rate levels, other CCS technologies become more economically attractive.     

Innovative energy technologies and climate policy in Germany

Due to the size and structure of its economy, Germany is one of the largest carbon emitters in the European Union. However, Germany is facing a major renewal and restructuring process in electricity generation. Within the next two decades, up to 50% of current electricity generation capacity may retire because of end-of-plant lifetime and the nuclear phase-out pact of 1998. Substantial opportunities, therefore, exist for deployment of advanced electricity generating technologies in both a projected baseline and in alternative carbon policy scenarios. We simulate the potential role of coal integrated gasification combined cycle (IGCC), natural gas combined cycle (NGCC), carbon dioxide capture and storage (CCS), and wind power within a computable general equilibrium model of Germany from the present through 2050. These advanced technologies and their role within a future German electricity system are the focus of this paper. We model the response of greenhouse gas emissions in Germany to various technology and carbon policy assumptions over the next few decades. In our baseline scenario, all of the advanced technologies except CCS provide substantial contributions to electricity generation. We also calculate the carbon price where each fossil technology, combined with CCS, becomes competitive. Constant carbon price experiments are used to characterize the model response to a carbon policy. This provides an estimate of the cost of meeting an emissions target, and the share of emissions reductions available from the electricity generation sector.     

Carbon capture and storage

Carbon capture and storage (CCS) covers a broad range of technologies that are being developed to allow carbon dioxide (CO₂) emissions from fossil fuel use at large point sources to be transported to safe geological storage, rather than being emitted to the atmosphere. Some key enabling contributions from technology development that could help to facilitate the widespread commercial deployment of CCS are expected to include cost reductions for CO₂ capture technology and improved techniques for monitoring stored CO₂. It is important, however, to realise that CCS will always require additional energy compared to projects without CCS, so will not be used unless project operators see an appropriate value for reducing CO₂ emissions from their operations or legislation is introduced that requires CCS to be used. Possible key advances for CO₂ capture technology over the next 50 years, which are expected to arise from an eventual adoption of CCS as standard practice for all large stationary fossil fuel installations, are also identified. These include continued incremental improvements (e.g. many potential solvent developments) as well as possible step-changes, such as ion transfer membranes for oxygen production for integrated gasifier combined cycle and oxyfuel plants.     

Effects of technological learning on future cost and performance of power plants with CO2 capture

This paper demonstrates the concept of applying learning curves in a consistent manner to performance as well as cost variables in order to assess the future development of power plants with CO₂ capture. An existing model developed at Carnegie Mellon University, which had provided insight into the potential learning of cost variables in power plants with CO₂ capture, is extended with learning curves for several key performance variables, including the overall energy loss in power plants, the energy required for CO₂ capture, the CO₂ capture ratio (removal efficiency), and the power plant availability. Next, learning rates for both performance and cost parameters were combined with global capacity projections for fossil-fired power plants to estimate future cost and performance of these power plants with and without CO₂ capture. The results of global learning are explicitly reported, so that they can be used for other purposes such as in regional bottom-up models. Results of this study show that IGCC with CO₂ capture has the largest learning potential, with significant improvements in efficiency and reductions in cost between 2001 and 2050 under the condition that around 3100 GW of combined cycle capacity is installed worldwide. Furthermore, in a scenario with a strict climate policy, mitigation costs in 2030 are 26, 11, 19 €/t (excluding CO₂ transport and storage costs) for NGCC, IGCC, and PC power plants with CO₂ capture, respectively, compared to 42, 13, and 32 €/t in a scenario with a limited climate policy. Additional results are presented for IGCC, PC, and NGCC plants with and without CO₂ capture, and a sensitivity analysis is employed to show the impacts of alternative assumptions on projected learning rates of different systems.     

Resource scarcity in palladium membrane applications for carbon capture in integrated gasification combined cycle units

Recently, many reviews on pre-combustion CO₂ capture (CCS) in an IGCC plant have been focused on the techno-economic performance of palladium-based membrane reactor modules downstream of conventional steam reforming or shift reactors. Although the determination and minimisation of the amount of palladium necessary for a specific power production capacity has been the target of many research studies, surprisingly little attention has been paid in the open literature to the availability of this metal in the large quantities required for large scale applications. To fill this gap, the scope of this work was to compare the amount of palladium needed for pre-combustion CCS with Pd-membranes and the available production capacity of palladium. Two specific techno-economic studies with a different net IGCC power output were selected from the literature. In each case, the amount of palladium that is necessary for the plant to be in operation was compared with the world supply and demand for palladium. The results show that even for a power plant of “only” 1 GWe net electricity production utilizing membranes with the best reported performance, a relatively large (∼0.7%) amount of palladium is required compared to the total world supply. Considering the total worldwide electricity production from fossil fuels (14,455 TWh in 2010) a tremendous increase in the world supply of Palladium would be required to redirect from the traditional IGCC power plants without CO₂ capture units to the new membrane technology. We conclude that large scale pre-combustion capture of CO₂ using palladium membranes seems to be unfeasible and research on Pd-based membrane reactors should focus on small(er) scale applications.     

Techno-economic evaluation of coal-to-liquids (CTL) plants with carbon capture and sequestration

Coal-to-liquids (CTL) processes that generate synthetic liquid fuels from coal are of increasing interest in light of the substantial rise in world oil prices in recent years. A major concern, however, is the large emissions of CO₂ from the process, which would add to the burden of atmospheric greenhouse gases. To assess the options, impacts and costs of controlling CO₂ emissions from a CTL plant, a comprehensive techno-economic assessment model of CTL plants has been developed, capable of incorporating technology options for carbon capture and storage (CCS). The model was used to study the performance and cost of a liquids-only plant as well as a co-production plant, which produces both liquids and electricity. The effect of uncertainty and variability of key parameters on the cost of liquids production was quantified, as were the effects of alternative carbon constraints such as choice of CCS technology and the effective price (or tax) on CO₂ emissions imposed by a climate regulatory policy. The efficiency and CO₂ emissions from a co-production plant also were compared to the separate production of liquid fuels and electricity. The results for a 50,000 barrels/day case study plant are presented.     

High efficiency electric power generation: The environmental role

Electric power generation system development is reviewed with special attention to plant efficiency. It is generally understood that efficiency improvement that is consistent with high plant reliability and low cost of electricity is economically beneficial, but its effect upon reduction of all plant emissions without installation of additional environmental equipment, is less well appreciated. As CO₂ emission control is gaining increasing acceptance, efficiency improvement, as the only practical tool capable of reducing CO₂ emission from fossil fuel plant in the short term, has become a key concept for the choice of technology for new plant and upgrades of existing plant. Efficiency is also important for longer-term solutions of reducing CO₂ emission by carbon capture and sequestration (CCS); it is essential for the underlying plants to be highly efficient so as to mitigate the energy penalty of CCS technology application. Power generating options, including coal-fired Rankine cycle steam plants with advanced steam parameters, natural gas-fired gas turbine-steam, and coal gasification combined cycle plants are discussed and compared for their efficiency, cost and operational availability. Special attention is paid to the timeline of the various technologies for their development, demonstration and commercial availability for deployment.     

Shell coal IGCCS with carbon capture: Conventional gas quench vs. innovative configurations

The Shell coal integrated gasification combined cycle (IGCC) based on the gas quench system is one of the most fuel flexible and energy efficient gasification processes because is dry feed and employs high temperature syngas coolers capable of rising high pressure steam. Indeed the efficiency of a Shell IGCC with the best available technologies is calculated to be 47–48%. However the system looses many percentage points of efficiency (up to 10) when introducing carbon capture. To overcome this penalty, two approaches have been proposed. In the first, the expensive syngas coolers are replaced by a “partial water quench” where the raw syngas stream is cooled and humidified via direct injection of hot water. This design is less costly, but also less efficient. The second approach retains syngas coolers but instead employs novel water–gas shift (WGS) configurations that requires substantially less steam to obtain the same degree of CO conversion to CO₂, and thus increases the overall plant efficiency. We simulate and optimize these novel configurations, provide a detailed thermodynamic and economic analysis and investigate how these innovations alter the plant’s efficiency, cost and complexity.     

CO2 capture study in advanced integrated gasification combined cycle

This paper presents the results of technical and economic studies in order to evaluate, in the French context, the future production cost of electricity from IGCC coal power plants with CO₂ capture and the resulting cost per tonne of CO₂ avoided. The economic evaluation shows that the total cost of base load electricity produced in France by coal IGCC power plants with CO₂ capture could be increased by 39% for ‘classical’ IGCC and 28% for ‘advanced’ IGCC. The cost per tonne of avoided CO₂ is lower by 18% in ‘advanced’ IGCC relatively to ‘classical’ IGCC. The approach aimed to be as realistic as possible for the evaluation of the energy penalty due to the integration of CO₂ capture in IGCC power plants. Concerning the CO₂ capture, six physical and chemical absorption processes were modeled with the Aspen Plus™ software. After a selection based on energy performance three processes were selected and studied in detail: two physical processes based on methanol and Selexol™ solvents, and a chemical process using activated MDEA. For ‘advanced’ IGCC operating at high-pressure, only one physical process is assessed: methanol.     

Techno-economic assessment on the fuel flexibility of a commercial scale combined cycle gas turbine integrated with a CO2 capture plant

Post-combustion carbon capture is a valuable technology, capable of being deployed to meet global CO₂ emissions targets. The technology is mature and can be retrofitted easily with existing carbon emitting energy generation sources, such as natural gas combined cycles. This study investigates the effect of operating a natural gas combined cycle plant coupled with carbon capture and storage while using varying fuel compositions, with a strong focus on the influence of the CO₂ concentration in the fuel. The novelty of this study lies in exploring the technical and economic performance of the integrated system, whilst operating with different fuel compositions. The study reports the design of a natural gas combined cycle gas turbine and CO₂ capture plant (with 30 wt% monoethanolamine), which were modelled using the gCCS process modelling application. The fuel compositions analysed were varied, with focus on the CO₂ content increasing from 1% to 5%, 7.5% and 10%. The operation of the CO₂ capture plant is also investigated with focus on the CO₂ capture efficiency, specific reboiler duty and the flooding point. The economic analysis highlights the effect of the varying fuel compositions on the cost of electricity as well as the cost of CO₂ avoided. The study revealed that increased CO₂ concentrations in the fuel cause a decrease in the efficiency of the natural gas combined cycle gas turbine; however, rising the CO₂ concentration and flowrate of the flue gas improves the operation of the capture plant at the risk of an increase in the flooding velocity in the column. The economic analysis shows a slight increase in cost of electricity for fuels with higher CO₂ contents; however, the results also show a reduction in the cost of CO₂ avoided by larger margins.