CO2‐Abtrennung für fossil befeuerte Kraftwerke

An overview of technologies for fossil fuel power plants with drastically reduced CO₂ emissions is given. Post combustion capture, Pre combustion capture, and Oxyfuel technology are introduced and compared. Current research results indicate that Post combustion capture may lead to slightly higher losses in power plant efficiency than the two other technologies. However, retrofitting of existing plants with Oxyfuel technology is complex and costly, and retrofitting of Pre combustion capture is not possible. On the other hand, Post combustion capture is suited for retrofitting. Based on the mature technology of reactive absorption, it can be implemented on a large scale in the near future. Therefore, Post combustion capture using reactive absorption is discussed here in some detail.     

Partial O2-fired coal power plant with post-combustion CO2 capture: A retrofitting option for CO2 capture ready plants

In the work presented in this paper, an alternative process concept that can be applied as retrofitting option in coal-fired power plants for CO₂ capture is examined. The proposed concept is based on the combination of two fundamental CO₂ capture technologies, the partial oxyfuel mode in the furnace and the post-combustion solvent scrubbing. A 330 MW_el Greek lignite-fired power plant and a typical 600 MW_el hard coal plant have been examined for the process simulations. In a retrofit application of the ECO-Scrub technology, the existing power plant modifications are dominated by techno-economic restrictions regarding the boiler and the steam turbine islands. Heat integration from processes (air separation, CO₂ compression and purification and the flue gas treatment) can result in reduced energy and efficiency penalties. In the context of this work, heat integration options are illustrated and main results from thermodynamic simulations dealing with the most important features of the power plant with CO₂ capture are presented for both reference and retrofit case, providing a comparative view on the power plant net efficiency and energy consumptions for CO₂ capture. The operational characteristics as well as the main figures and diagrams of the plant’s heat balances are included.     

Post-combustion CO2 capture with chemical absorption: A state-of-the-art review

Global concentration of CO₂ in the atmosphere is increasing rapidly. CO₂ emissions have an impact on global climate change. Effective CO₂ emission abatement strategies such as Carbon Capture and Storage (CCS) are required to combat this trend. There are three major approaches for CCS: post-combustion capture, pre-combustion capture and oxyfuel process. Post-combustion capture offers some advantages as existing combustion technologies can still be used without radical changes on them. This makes post-combustion capture easier to implement as a retrofit option (to existing power plants) compared to the other two approaches. Therefore, post-combustion capture is probably the first technology that will be deployed. This paper aims to provide a state-of-the-art assessment of the research work carried out so far in post-combustion capture with chemical absorption. The technology will be introduced first, followed by required preparation of flue gas from power plants to use this technology. The important research programmes worldwide and the experimental studies based on pilot plants will be reviewed. This is followed by an overview of various studies based on modelling and simulation. Then the focus is turned to review development of different solvents and process intensification. Based on these, we try to predict challenges and potential new developments from different aspects such as new solvents, pilot plants, process heat integration (to improve efficiency), modelling and simulation, process intensification and government policy impact.     

An overview on oxyfuel coal combustion—State of the art research and technology development

Oxyfuel combustion is seen as one of the major options for CO₂ capture for future clean coal technologies. The paper provides an overview on research activities and technology development through a fundamental research underpinning the Australia/Japan Oxyfuel Feasibility Project. Studies on oxyfuel combustion on a pilot-scale furnace and a laboratory scale drop tube furnace are presented and compared with computational fluid dynamics (CFD) predictions. The research has made several contributions to current knowledge, including; comprehensive assessment on oxyfuel combustion in a pilot-scale oxyfuel furnace, modifying the design criterion for an oxy retrofit by matching heat transfer, a new 4-grey gas model which accurately predicts emissivity of the gases in oxy-fired furnaces has been developed for furnace modelling, the first measurements of coal reactivity comparisons in air and oxyfuel at laboratory and pilot-scale; and predictions of observed delays in flame ignition in oxy-firing.     

Dynamic modelling and analysis of post-combustion CO2 chemical absorption process for coal-fired power plants

Post-combustion capture by chemical absorption using MEA solvent remains the only commercial technology for large scale CO₂ capture for coal-fired power plants. This paper presents a study of the dynamic responses of a post-combustion CO₂ capture plant by modelling and simulation. Such a plant consists mainly of the absorber (where CO₂ is chemically absorbed) and the regenerator (where the chemical solvent is regenerated). Model development and validation are described followed by dynamic analysis of the absorber and regenerator columns linked together with recycle. The gPROMS (Process Systems Enterprise Ltd.) advanced process modelling environment has been used to implement the proposed work. The study gives insights into the operation of the absorber-regenerator combination with possible disturbances arising from integrated operation with a power generation plant. It is shown that the performance of the absorber is more sensitive to the molar L/G ratio than the actual flow rates of the liquid solvent and flue gas. In addition, the importance of appropriate water balance in the absorber column is shown. A step change of the reboiler duty indicates a slow response. A case involving the combination of two fundamental CO₂ capture technologies (the partial oxyfuel mode in the furnace and the post-combustion solvent scrubbing) is studied. The flue gas composition was altered to mimic that observed with the combination. There was an initial sharp decrease in CO₂ absorption level which may not be observed in steady-state simulations.     

Impact of liquid absorption process development on the costs of post-combustion capture in Australian coal-fired power stations

Australian power generators produce approximately 170 TWh per annum of electricity using black and brown coals that accounts for 170 Mtonne of CO₂ emissions per annum or over 40% of anthropogenic CO₂ emissions in Australia. This paper describes the results of a techno-economic evaluation of liquid absorption based post-combustion capture (PCC) processes for both existing and new pulverised coal-fired power stations in Australia. The overall process designs incorporate both the case with continuous capture and the case with the flexibility to switch a CO₂ capture plant on or off depending upon the demand and market price for electricity, and addresses the impact of the presently limited emission controls on the process cost. The techno-economic evaluation includes both air and water cooled power and CO₂ capture plants, resulting in cost of power generation for the situations without and with PCC. Whilst existing power plants in Australia are all water cooled sub-critical designs, the new power plants are deemed to range from supercritical single reheat to ultra-supercritical double reheat designs, with a preference for air-cooling. The process evaluation also includes a detailed sensitivity analysis of the thermodynamic properties of liquid absorbent for CO₂ on the overall costs. The results show that for a meaningful decrease in the efficiency and cost penalties associated with the post combustion CO₂ capture, a novel liquid sorbent will need to have heat of absorption/desorption, sensible heat and heat of vaporisation around 50% less in comparison with 30% (w/w) aqueous MEA solvent. It also shows that the impact of the capital costs of PCC processes is quite large on the added cost of generation. The results can be used to prioritise PCC research in an Australian context.     

Modeling of circulating fluidized beds systems for post‐combustion CO2 capture via temperature swing adsorption

The technology of circulating fluidized beds (CFBs) is applied to temperature swing adsorption (TSA) processes for post‐combustion CO₂ capture employing a commercial zeolite sorbent. Steady state operation is simulated through a one‐dimensional model, which combines binary adsorption with the CFB dynamics. Both single step and multi‐step arrangements are investigated. Extensive sensitivity analyses are performed varying the operating conditions, in order to assess the influence of the main operational parameters. The results reveal a neat superiority of multi‐step configurations over the standard one, in terms of both separation performance and efficiency. Compared to fixed‐bed TSA systems, CFB TSA features a high compactness degree. However, product purity levels are limited compared to the best performing fixed‐bed processes, and heat management within the system appears to be a major issue. As regards energy efficiency, CFB systems place themselves in between the most established absorption‐based technologies and the fixed‐bed TSA. © 2017 The Authors AIChE Journal published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers AIChE J, 64: 1744–1759, 2018     

Chemical functionalization strategies for carbon dioxide capture in microporous organic polymers

We review the design and use of microporous polymers for pre‐ and post‐combustion capture of CO₂. Microporous organic polymers are promising candidates for CO₂ capture materials. They have good physicochemical stabilities and high surface areas. Ultrahigh‐surface‐area microporous organic polymers could find use in pre‐combustion capture, while networks with lower surface areas but higher heats of sorption for CO₂ might be more relevant for lower pressure, post‐combustion capture. We discuss strategies for enhancing CO₂ uptakes including increasing surface area, chemical functionalization to provide high‐enthalpy binding sites and the potential for pore size tuning. © 2013 Society of Chemical Industry     

Economic implications of oxyfuel application in a lignite-fired power plant

Scope of the work presented in this paper is to examine and evaluate the application of the oxyfuel combustion CO₂ capture technology in a lignite-fired power plant from an economic point of view. Results from simulations dealing with the most important features for CO₂ reduction are performed. The operational characteristics, the efficiency penalties as well as the net efficiency reduction emerging from the Greenfield application of the oxyfuel technology are presented.CO₂ capture costs and the energy requirements associated with the oxyfuel method affect significantly the cost of electricity. This paper focuses on the analysis of the techno-economic factors that result in the increase of the cost of electricity in comparison with the conventional air-fired power plant. For this reason a typical Greek lignite power plant is used as a reference case. Any technical, economic and financial assumptions applied provide a common basis for both power plants (i.e., conventional and oxyfuel) for the assessment of the change of the cost of electricity and the CO₂ capture cost. The oxyfuel simulations are performed by taking into account the adoption of measures for the exploitation of heat that would otherwise be wasted. Such measures concern both the water/steam cycle and the gas flows (e.g., the oxygen flow). Heat integration from processes - such as the air separation, the CO₂ compression and purification and the flue gas treatment - is adopted in order to lower as much as possible the efficiency penalty.The cycle calculations have been performed using the thermodynamic cycle calculation software ENBIPRO (ENergie-BIllanz-PROgram). ENBIPRO is a powerful tool for heat and mass balance solving of complex thermodynamic circuits, calculation of efficiency, exergetic and exergoeconomic analysis of power plants. The software code models all pieces of equipment that usually appear in power plant installations and can accurately calculate all thermodynamic properties (temperature, pressure, enthalpy) at each node of the thermodynamic circuit, power consumption of each component, flue gas composition, etc. The code has proven its validity by accurately simulating a large number of power plants and through comparison of the results with other commercial software (Stamatelopoulos GN. Calculation and optimisation of power plant thermodynamic cycles. VDI-Regulations. Series 6, No. 340. Braunchweig, Mechanical Engineering Department; 1996 [in German]).     

Comparative assessment of sub-critical versus advanced super-critical oxyfuel fired PF boilers with CO2 sequestration facilities

This work focuses on the techno-economic assessment of bituminous coal fired sub- and super-critical pulverised fuel boilers from an oxyfuel based CO₂ capture point of view. At the initial stage, two conventional power plants with a nominal power output of above 600 MWe based on the above steam cycles are designed, simulated and optimised. Built upon these technologies, CO₂ capture facilities are incorporated within the base plants resulting in a nominal power output of 500 MWe. In this manner, some sensible heat generated in the air separation unit and the CO₂ capture train can be redirected to the steam cycle resulting in a higher plant efficiency. The simulation results of conventional sub- and super-critical plants are compared with their CO₂ capture counterparts to disclose the effect of sequestration on the overall system performance attributes. This systematic approach allows the investigation of the effects of the CO₂ capture on both cycles. In the literature, super-critical plants are often considered for a CO₂ capture option. These, however, are not based on a systematic evaluation of these technologies and concentrate mainly on one or two key features. In this work several techno-economic plant attributes such as the fuel consumptions, the utility usages, the plant performance parameters as well as the specific CO₂ generation and capture rates are calculated and weighed against each other. Finally, an economic evaluation of the system is conducted along with sensitivity analyses in connection with some key features such as discounted cash flow rates, capital investments and plant efficiencies as well as fuel and operating costs.     

Simulation of a calcium looping CO2 capture process for pressurized fluidized bed combustion

The Canadian regulations on carbon dioxide emissions from power plants aim to lower the emissions from coal-fired units down to those of natural gas combined cycle (NGCC) units. Since coal is significantly more carbon intensive than natural gas, coal-fired plants must operate at higher net efficiencies and implement carbon capture to meet the new regulations. Calcium looping (CaL) is a promising post-combustion carbon capture (PCC) technology that, unlike other capture processes, generates additional power. By capturing carbon dioxide at elevated temperatures, the energy penalty that carbon capture technologies inherently impose on power plant efficiencies is significantly reduced. In this work, the CO₂ capture performance of a calcium-based sorbent is determined via thermogravimetric analysis under relatively high carbonation and low calcination temperatures. The results are used in an aspenONE™ simulation of a CaL process applied to a pressurized fluidized bed combustion (PFBC) system at thermodynamic equilibrium. The combustion of both natural gas and coal are considered for sorbent calcination in the CaL process. A sensitivity analysis on several process parameters, including sorbent feed rate and carbonator operating pressure, is undertaken. The energy penalty associated with the capture process ranges from 6.8–11.8 percentage points depending on fuel selection and operating conditions. The use of natural gas results in lower energy penalties and solids circulation rates, while operating the carbonator at 202 kPa(a) results in the lowest penalties and drops the solids circulations rates to below 1000 kg/s.     

燃烧尾气后处理的反应溶剂型大型工业CO2吸收塔工艺技术进展

介绍了工业化经济型CO₂吸收塔的实体案例,总结近十年来工业化CO₂吸收塔的化工装置以及工程技术进展。系统介绍了CO₂吸收塔的化工工艺装置在运行中经常遇到的技术问题以及相应的解决方案,并分析近十年来几类技术发展,分别是溶液降解和降解产物处理技术、气体排放尾气的采样和分析技术、吸收剂主体组分分析技术、降低总体能耗的催化吸收-解吸技术。通过分析可知,利用固体矿物和生物催化剂是降低能耗的有效方法,但存在大量技术问题有待完善和解决。总之,这一系列的化工工艺技术的发展和进步,会为完善经济型吸收塔提供更多可信的实际数据。因此,燃烧尾气后处理的溶剂型CO₂吸收化工工艺装置必然朝着更小的反应器(吸收塔)和更低的能耗发展目标前进,从而实现该装置的高效率和低成本运行。     

Optimal design of combined cycle power plants with fixed-bed chemical-looping combustion reactors

Process intensification options are explored for near-carbon-neutral, natural-gas-fueled combined cycle (CC) power plants, wherein the conventional combustor is replaced by a series of chemical-looping combustion (CLC) reactors. Dynamic modeling and optimization are deployed to design CLC-CC power plants with optimal configuration and performance. The overall plant efficiency is improved by optimizing the CLC reactor design and operation, and modifying the CC plant configuration and design. The optimal CLC-CC power plant has a time-averaged efficiency of 52.52% and CO₂ capture efficiency of 96%. The main factor that limits CLC-CC power plant efficiency is the reactor temperature, which is constrained by the oxygen carrier material. CLC exhaust gas temperature during heat removal and gas compressor to gas turbine pressure ratio are the most important operating variables and if properly tuned, CLC-CC power plants can reach high thermodynamic efficiencies. © 2018 American Institute of Chemical Engineers AIChE J, 65: e16516 2019     

Dynamic modelling of CO2 absorption for post combustion capture in coal-fired power plants

Power generation from fossil fuel-fired power plants is the largest single source of CO₂ emissions. Post combustion capture via chemical absorption is viewed as the most mature CO₂ capture technique. This paper presents a study of the post combustion CO₂ capture with monoethanolamine (MEA) based on dynamic modelling of the process. The aims of the project were to compare two different approaches (the equilibrium-based approach versus the rate-based approach) in modelling the absorber dynamically and to understand the dynamic behaviour of the absorber during part load operation and with disturbances from the stripper. A powerful modelling and simulation tool gPROMS was chosen to implement the proposed work. The study indicates that the rate-based model gives a better prediction of the chemical absorption process than the equilibrium-based model. The dynamic simulation of the absorber indicates normal absorber column operation could be maintained during part load operation by maintaining the ratio of the flow rates of the lean solvent and flue gas to the absorber. Disturbances in the CO₂ loading of the lean solvent to the absorber significantly affect absorber performance. Further work will extend the dynamic modelling to the stripper for whole plant analysis.     

Oxyfuel boiler design in a lignite-fired power plant

In the context of CO₂ capture and storage, the oxyfuel technology provides a promising option applicable in centralised power production schemes. This technology is based on combustion with pure oxygen instead of air and the flue gas mainly consists of CO₂ and H₂O. The work presented in this paper is focused in the application of the oxyfuel technology in a lignite-fired power plant. Significant design issues are the required extended flue gas recirculation in order to provide the ballasting effect of the absent N₂ and moderate the furnace temperatures. Therefore, a modified design of heat exchange surfaces of the oxyfuel steam boiler was formulated and was compared to a conventional air-fired boiler. A typical modern Greek air-fired power plant has been used as reference. The dominating factors that affect the dimensioning of the oxyfuel boiler are the higher radiative heat transfer - due to the high concentrations of CO₂ and H₂O in the flue gas - and the different flue gas mass flow, compared to a conventional air-fired boiler. For the determination of the thermodynamic cycle characteristics, simulations were made with the use of a thermodynamic cycle calculation software [Stamatelopoulos GN. Calculation and optimisation of power plant thermodynamic cycles, VDI-Regulations, Series 6, Nr. 340. Braunchweig, Mechanical Engineering Department; 1996 [in German]].     

Syngas combustion in a 500 Wth Chemical-Looping Combustion system using an impregnated Cu-based oxygen carrier

Chemical-Looping Combustion (CLC) is an emerging technology for CO₂ capture because separation of this gas from the other flue gas components is inherent to the process and thus no energy is expended for the separation. For its use with coal as fuel in power plants, a process integrated by coal gasification and CLC would have important advantages for CO₂ capture. This paper presents the combustion results obtained with a Cu-based oxygen carrier in a continuous operation CLC plant (500 Wth) using syngas as fuel. For comparison purposes pure H₂ and CO were also used. Tests were performed at two temperatures (1073 and 1153 K), different solid circulation rates and power inputs. Full syngas combustion was reached at 1073 K working at f higher than 1.5. The syngas composition had small effect on the combustion efficiency. This result seems to indicate that the water gas shift reaction acts as an intermediate step in the global combustion reaction of the syngas. The results obtained after 40 h of operation showed that the copper-based oxygen carrier prepared by impregnation could be used in a CLC plant for syngas combustion without operational problems such as carbon deposition, attrition, or agglomeration.     

Comprehensive process design study for layered‐NOX‐control in a tangentially coal fired boiler

As emissions regulations for coal‐fired power plants become stricter worldwide, layering combustion modification and post‐combustion NO_X control technologies can be an attractive option for efficient and cost‐effective NO_X control in comparison to selective catalytic reduction (SCR) technology. The layered control technology approach designed in this article consists of separate overfire air (SOFA), reburn, and selective noncatalytic reduction (SNCR). The combined system can achieve up to 75% NO_X reduction. The work presented in this article successfully applied this technology to NRG Somerset Unit 6, a 120‐MW tangential coal‐fired utility boiler, to reduce NO_X emissions to 0.11 lb/MMBtu (130 mg/Nm³), well under the US EPA SIP Call target of 0.15 lb/MMBtu. The article reviews an integrated design study for the layered system at Somerset and evaluates the performance of different layered‐NO_X‐control scenarios including standalone SNCR (baseline), separated overfire air (SOFA) with SNCR, and gas reburn with SNCR. Isothermal physical flow modeling and computational fluid dynamics simulation (CFD) were applied to understand the boiler flow patterns, the combustible distributions and the impact of combustion modifications on boiler operation and SNCR performance. The modeling results were compared with field data for model validation and verification. The study demonstrates that a comprehensive process design using advanced engineering tools is beneficial to the success of a layered low NO_X system. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Crisp and fuzzy integer programming models for optimal carbon sequestration retrofit in the power sector

Carbon capture and storage (CCS) is one of the interim technologies to mitigate greenhouse gas emissions from stationary sources such as power plant and large industrial facilities. CCS allows for continued utilization of fossil fuels (e.g. coal, natural gas and oil), which are still relatively inexpensive and reliable in comparison to inherently low-carbon renewable resources (e.g. wind, solar etc.). On the other hand, retrofitting power plants for carbon capture (CC) entails major capital costs as well as reduction of thermal efficiency and power output. This paper presents integer programming optimization models for planning the retrofit of power plants at the regional, sectoral or national level. In addition to the base case (i.e., non-fuzzy or crisp) formulation, two fuzzy extensions are given to account for the inherent conflict between environmental and economic goals, as well as parametric uncertainties pertaining to the emerging CC technologies. Case studies are shown to illustrate the modeling approach.     

Carbon capture from stationary power generation sources: A review of the current status of the technologies

The world will need greatly increased energy supply in the future for sustained economic growth, but the related CO₂ emissions and the resulting climate changes are becoming major concerns. CO₂ is one of the most important greenhouse gases that is said to be responsible for approximately 60% of the global warming. Along with improvement of energy efficiency and increased use of renewable energy sources, carbon capture and sequestration (CCS) is expected to play a major role in curbing the greenhouse gas emissions on a global scale. This article reviews the various options and technologies for CO₂ capture, specifically for stationary power generation sources. Many options exist for carbon dioxide capture from such sources, which vary with power plant types, and include post-combustion capture, pre-combustion capture, oxy fuel combustion capture, and chemical looping combustion capture. Various carbon dioxide separation technologies can be utilized with these options, such as chemical absorption, physical absorption, adsorption, and membrane separation. Most of these capture technologies are still at early stages of development. Recent progress and remaining challenges for the various CO₂ capture options and technologies are reviewed in terms of capacity, selectivity, stability, energy requirements, etc. Hybrid and modified systems hold huge future potentials, but significant progress is required in materials synthesis and stability, and implementations of these systems on demonstration plants are needed. Improvements and progress made through applications of process systems engineering concepts and tools are highlighted and current gaps in the knowledge are also mentioned. Finally, some recommendations are made for future research directions.     

Techno-economic comparison of three technologies for pre-combustion CO2 capture from a lignite-fired IGCC

This paper compares the techno-economic performances of three technologies for CO₂ capture from a lignite-based IGCC power plant located in the Czech Republic: (1) Physical absorption with a Rectisol-based process; (2) Polymeric CO₂-selective membrane-based capture; (3) Low-temperature capture. The evaluations show that the IGCC plant with CO₂ capture leads to costs of electricity between 91 and 120 €·MWh⁻¹, depending on the capture technology employed, compared to 65 €·MWh⁻¹ for the power plant without capture. This results in CO₂ avoidance costs ranging from 42 to 84 €·t_CO2,avoided⁻¹ , mainly linked to the losses in net power output. From both energy and cost points of view, the low-temperature and Rectisol based CO₂ capture processes are the most efficient capture technologies. Furthermore, partial CO₂ capture appears as a good mean to ensure early implementation due to the limited increase in CO₂ avoidance cost when considering partial capture. To go beyond the two specific CO₂-selective membranes considered, a cost/membrane property map for CO₂-selective membranes was developed. This map emphasise the need to develop high performance membrane to compete with solvent technology. Finally, the cost of the whole CCS chain was estimated at 54 €·t_CO2,avoided⁻¹ once pipeline transport and storage are taken into consideration.