Hydrogen and power co-generation based on syngas and solid fuel direct chemical looping systems

Transcription

1 Hydrogen and power co-generation based on syngas and solid fuel direct chemical looping systems Calin-Cristian Cormos Babeş Bolyai University, Faculty of Chemistry and Chemical Engineering 11 Arany Janos, RO , Cluj Napoca, Romania New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 1

2 Outline 1. Introduction 2. Plant configurations & major design assumptions 3. Plant modelling, simulation and thermal integration 4. Evaluation of hydrogen and power co-generation 5. Development issues 6. Conclusions New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 2

3 I. Introduction The following work was performed within the project: Innovative methods for chemical looping carbon dioxide capture applied to energy conversion processes for decarbonised energy vectors poly-generation Specific project objectives: - Investigation of coal and biomass / solid wastes co-processing via gasification and combustion - Energy vectors poly-generation (power, hydrogen, SNG, heat, FT fuel) - Evaluation of various carbon capture technologies - Techno-economical and environmental evaluations of energy vectors poly-generation with CCS New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 3

4 Chemical looping conversion Main advantages: - Inherent CO 2 capture - High temp. heat recovery - Fuel versatility - Poly-generation capability New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 4

5 II. Plant configurations of H 2 and power co-generation with chemical looping systems Syngas-based chemical looping Syngas Steam Steam turbine Power Steam Condensate Steam Fuel (syngas) reactor Fe 2 O 3 Fe/FeO Air Air reactor Steam reactor Fe 3 O 4 Exhaust air Condensate CO 2 to storage CO 2 Drying and Compression H 2 compression Combined Cycle Gas Turbine Purified hydrogen Power New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 5

6 Details of syngas-based chemical looping cycle Fe 2 O 3 Fe 2 O 3 + CO + H 2 Fe / FeO + H 2 O + CO o C, 30 bar Syngas Fe / FeO + H 2 O Fe 3 O 4 + H o C, 28 bar Steam Fe/FeO Fuel reactor Steam reactor CO 2, H 2 O H 2, H 2 O Air reactor Air N 2, O 2 Fe 3 O 4 + O 2 Fe 2 O o C, 30 bar Fe 3 O 4 New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 6

7 Solid fuel direct chemical looping conversion Solid fuels (coal, lignite, biomass) Drying & Grounding Steam Enhancer gas (e.g. steam, CO 2 ) Steam turbine Power Steam Condensate Steam Fuel reactor Fe 2 O 3 Fe/FeO Air Air reactor Steam reactor Fe 3 O 4 Spent solid (incl. ash) Fresh oxygen carrier Exhaust air Condensate CO 2 to storage CO 2 Drying and Compression H 2 compression Combined Cycle Gas Turbine Purified hydrogen Power New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 7

8 Details of solid fuel direct chemical looping cycle Fe 2 O 3 + Solid fuel Fe / FeO + H 2 O + CO o C, 30 bar Fe 3 O 4 + O 2 Fe 2 O o C, 30 bar Fe / FeO + H 2 O Fe 3 O 4 + H o C, 28 bar New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 8

9 Benchmark case: IGCC with Selexol TM -based pre-combustion CO 2 capture New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 9

10 Major design assumptions 1. Plant size: ~ 450 MW net power; MW H 2 (LHV) 2. Entrained-flow gasifier: Dry fed gas quench type 3. Gas turbine: 1 x M701G2 (MHI) 4. Carbon capture rate: >90 % 5. Carbon capture: Ilmenite (oxygen carrier) / Selexol TM 6. CO 2 purity & pressure: >95 % (vol.) / 120 bar 7. H 2 purity & pressure: >99.95 % (vol.) / 70 bar 8. Fuel types: High grade coal, biomass (sawdust) New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 10

11 Investigated case studies Investigated coal-based power plant concepts for hydrogen and power co-generation with carbon capture: Case 1 IGCC with syngas-based chemical looping Case 2 Coal direct chemical looping conversion Case 3 IGCC with Selexol TM -based pre-combustion CO 2 capture New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 11

12 III. Plant modeling, simulation and thermal integration Investigated case studies were simulated using process flow modelling software ChemCAD and Thermoflex Power island Chemical looping & CO 2 drying and compression Gasification island & Syngas conditioning New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 12 Case 1: Syngas-based chemical looping

13 Energy integration aspects Investigated energy integration aspects: - Steam integration from gasification island, syngas conditioning line and chemical looping unit into CCGT steam cycle (Rankine cycle) - Heat and power integration for carbon capture unit (oxygen carrier regeneration, captured CO 2 stream drying and compression) - Air integration between Air Separation Unit (ASU) and GT compressor (GT air bleed) - Hydrogen-fuelled Combined Cycle Gas Turbine (CCGT) New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 13

14 Optimization of plant energy efficiency by heat and power integration Case 2: Composite curves for chemical looping unit New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 14

15 Optimization of plant energy efficiency by heat and power integration Case 2: Composite curves for hydrogen-fuelled CCGT New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 15

16 Net electrical efficiency (%) Evaluation of ASU GT air integration Cases 1 & Pros: - Increased efficiency - Increased power output - Reduced investment costs (save ASU air compressor) Air integration degree (%) Case 1: Syngas-based chemical looping New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 16 Cons: - Lengthy start-up - Less operational flexibility - Lower availability

17 IV. Evaluation of hydrogen and power co-generation Investigated power plant concepts: Case 1 IGCC with syngas-based chemical looping Case 2 Coal direct chemical looping conversion Case 3 IGCC with Selexol TM -based pre-combustion CO 2 capture New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 17

18 Power generation only Case 1 Case 2 Case 3 Coal flowrate t/h Coal thermal energy (LHV) MW th Gas turbine output (1 x M701G2) MW e Steam turbine output MW e Air expander output MW e Ancillary power demand MW e Net electric power MW e Net electrical efficiency % Carbon capture rate % CO 2 specific emissions Kg / MWh New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 18

19 Hydrogen and power co-generation - Case 2 (coal direct chemical looping) Power Coal flowrate t/h Power & Hydrogen Coal thermal energy (LHV) MW th Gas turbine output (1 x M701G2) MW e Steam turbine output MW e Air expander output MW e Hydrogen output MW th Ancillary power demand MW e Net electric power MW e Net electrical efficiency % Hydrogen efficiency % Cumulative efficiency % Carbon capture rate % CO 2 specific emissions Kg / MWh New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 19

20 Efficiency [%] Variation of plant performances vs. hydrogen and power co-production ratio Hydrogen co-generation ratio [MW] Variation of electrical, hydrogen and cumulative energy efficiencies vs. hydrogen output (Case 2) New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 20 Electrical efficiency Hydrogen efficiency Cumulative efficiency

21 Evaluation of captured CO 2 composition Evaluation of various transport gases for dry-fed gasifier and coal direct chemical looping conversion New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 21

22 Estimation of capital costs Capital cost presented as a power law of capacity: Q C E CB *( ) Q B M C E equipment cost with capacity Q C B known base cost for equipment with capacity Q B M constant depending on equipment type Total investment cost per kw gross / net: TIC TIC per per kw( gross) New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 22 Total investment cos t Gross power output Total investment cos t kw( net ) Net power output

23 Estimation of operational & maintenance (O&M) costs Operational & maintenance (O&M) costs include: - Fuel used and fluxing materials - Chemicals (for BFW, process & CW, solvents etc.) - Catalysts (for WGS, Claus plant, COS hydrolysis etc.) - Oxygen carrier (illmenite) - Direct operating labor costs - Maintenance, overhead charges etc. O&M costs are allocated as fixed and variable costs New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 23

24 Economic performances - Power generation only Case 1 Case 2 Case 3 Total investment cost MM Total investment cost per kw gross / kw Total investment cost per kw net / kw Total fixed O&M costs (year) M / y Total fixed O&M costs (MWh net) / MWh Total variable O&M costs (year) M / y Total variable O&M costs (MWh net) / MWh Total fixed and variable costs (year) M / y Total fixed and variable costs (MWh net) / MWh New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 24

25 Estimation of levelised cost of electricity (LCOE) and CO 2 capture costs CO 2 capture costs presented as CO 2 removal and avoided costs: CO2 removal cos t LCOE with CCS CO 2 LCOE removed withoutccs CO2 avoided cos t CO 2 LCOE emissions with CCS withoutccs LCOE CO 2 withoutccs emissions with CCS Costs Units No CCS Case 1 Case 2 Case 3 Cost of electricity / MWh CO 2 removal cost / t CO 2 avoided cost / t New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 25

26 V. Development issues Chemical looping techniques show good potential for high energy conversion efficiencies for both syngas and direct solid fuel applications However, significant developments are needed from current state of the art (up to 1-10 MW), e.g. oxygen carrier development & manufacture, fuel conversion, spent oxygen carrier utilisation, design issues etc. Direct solid fuel chemical looping plants would have important similarities to circulated fluidised bed (CFB), which is a commercial technology up to 500 MW e Syngas-based chemical looping concept looks simpler in term of gas-solid system (e.g. higher fuel conversion, no ash removal required, lower oxygen carrier deactivation) New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 26

27 Direct solid fuel chemical looping is a promising solution for energy efficient full biomass conversion Case 2 Biomass (sawdust) flowrate t/h Biomass thermal energy (LHV) MW th Gas turbine output (1 x M701G2) MW e Steam turbine output MW e Air expander output MW e Ancillary power demand MW e Net electric power MW e Net electrical efficiency % Carbon capture rate % CO 2 specific emissions Kg / MWh 3.60 New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 27

28 Economic performances for direct biomass chemical looping conversion Biomass Coal Total investment cost MM Total investment cost per kw gross / kw Total investment cost per kw net / kw Total fixed O&M costs (year) M / y Total fixed O&M costs (MWh net) / MWh Total variable O&M costs (year) M / y Total variable O&M costs (MWh net) / MWh Total fixed and variable costs (year) M / y Total fixed and variable costs (MWh net) / MWh New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 28

29 VI. Conclusions Direct solid fuel and syngas chemical looping concepts are promising solutions to deliver high energy efficiency together with almost total fuel decarbonisation Modelling, simulation and heat and power integration were used to asses and optimize the techno-economic and environmental performances Hydrogen and power co-generation capability is a promising solution to improve the techno-economic and environmental power plant performances Direct solid fuel chemical looping conversion can be successfully applied for 100% biomass / solid waste energy applications New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 29

30 Thank you for your attention! Contact: Calin-Cristian Cormos This work has been supported by Romanian National Authority for Scientific Research, CNCS UEFISCDI, through grants no. PN-II-ID-PCE and PNII-CT-ERC ; 2ERC New CCT Horizons 2013, Salonic, in Gasification, Greece Rotterdam 30