Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Advanced energy systems Studio, modellizzazione e analisi di componenti e sistemi innovativi a bassa emissione di CO 2 per la conversione termomeccanica dell’energia Marco Gambini, Michela Vellini Dipartimento di Ingegneria Industriale Università di Roma “Tor Vergata” M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Introduction Environmental situation Increasing amounts of gases, such as CO2, in the earth's atmosphere bring the risk of enhancing the natural greenhouse effect, leading to changes in the climate. Actual energy policy The size of climate changes and their impact are not fully understood. Nevertheless, it is generally accepted that the level of greenhouse gases in the atmosphere must be stabilised in order to prevent dangerous anthropogenic interference with the climate system. Power generation sector Fossil fuels are likely to play a major role in global energy supply and especially in power energy sector in the near-medium term future. But fossil fuel are also major source of anthropogenic CO2 emission into the atmosphere. A strong abatement of these emissions must be achieved in these and in the next few years CO2 mitigation options in power generation A broad range of options is available for reducing carbon dioxide emissions to the atmosphere. They are: • improving the efficiency of energy use • switching to less carbon-intensive fuel (e.g. from coal to natural gas) • increasing the application of renewable energy sources and the nuclear power • removal of CO2 from fossil fuel power plants M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” • PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 CO2 CAPTURE AND STORAGE It’s the most important option to reduce substantially carbon dioxide emissions. Capture and storage of CO2 is now technically feasible. Carbon dioxide removal techniques The methodologies proposed up to now are: • CO2 removal process treating the products of combustion from conventional fossil fuel power plants or the process gases (option A) • using semi-closed cycles where the working fluid is prevalently CO2; the excess CO2 produced in the combustion process is totally captured (option B) • Fossil fuel decarbonization (option C) M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 G.I.ST. Cycle Study and proposal of new advanced power plants able to attain high performance and low ambient impact. G.I.ST. (Gas Injection Steam) is a new mixed cycle where there is a topping heating of steam by means of an internal combustion • • • • • p=cost. T pressure drop during mixing steam and exhaust gases (process A-B) topping temperature of the cycle very high (point B) final point of expansion (point C) is superheated steam (together with incondesable gases) de-superheating of mixuture steam and incondensable gases after expansio (process C-D) condensation (separation and recovery of the water) not isothermal (process D-E). B A C D E S M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 G.I.ST. Cycle aria CHP IC 0A CLP • Conventional high pressure steam turbine • Regenerative re-heating • Bottoming cycle • “bottoming cycle”, fed by heat of the mixture steam and incondensable gases at the exit of the medium pressure turbine comb. 1A CC gas sat. 1 3S 6G THP TMP 6S comb. TSG TLP 2 8 6R 7 SEP 10 9 3 5 4 • Efficiency: 38.3% • boiler/tot : 74% • msteam/mtot : 67% (by weight at SEP inlet) M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 G.I.ST. Cycle Ciclo termodinamico del vapore (diagramma T,s) aria 1000 950 p=cost. 1 900 CHP IC 0A CLP 850 800 700 TEMPERATURA (°C) comb. riscaldamenti tramite combustibile 750 1A c.i. 650 CC c.e. 600 2 6g 550 3S 6s 6G 500 TMP 6S TSG 350 TLP 2 8 6R 400 7 7 300 250 SEP 6r 200 150 4 100 0 THP comb. 450 50 gas sat. 1 10 3 3 10 9 0.0 3i 5 8 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 5 9.0 10.0 ENTROPIA (KJ/KG °C) M. Gambini, M. Vellini – Advanced Energy Systems 4 9 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 G.I.ST. Cycle Profili di temperatura nel separatore aria 650 0A 600 CHP 550 IC CLP TEMPERATURA (°C) 500 comb. 450 1A CC 400 gas sat. 1 3S RH 350 6G 300 THP TMP 6S comb. TSG 2 8 6R 250 TLP 7 separazione dell'acqua 200 150 SEP 100 10 3 50 0 5 0 10 20 30 40 50 60 70 80 90 100 CALORE SCAMBIATO (%) M. Gambini, M. Vellini – Advanced Energy Systems 4 9 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 G.I.ST. Cycle (AMC) comb. CLP aria CHP 1A IC 1 CC1 CC2 0A 2P • Gas-turbine with reheating and steam injection in the first combustion chamber • Conventional high pressure steam turbine • HRSG for steam production • Atmospheric SEP for water recovery 2 TMP1 THP 6 TMP2 2R 6S SEP 6R 5 gas 4 3 • Efficiency: 57.0% • msteam/(mair+ msteam): 25% (by weight) M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 G.I.ST. Cycle Ciclo termodinamico del vapore (diagramma T,s) 1300 comb. 2p 1 CLP p=cost. 1200 riscaldamenti tramite combustibile 1100 aria 1000 CHP 1A IC 1 CC1 CC2 0A 2P 2 TEMPERATURA (°C) 900 TMP1 THP 2 800 TMP2 2r 6 700 600 6 2R 6S 6s 500 SEP 400 6R 300 6r 200 100 5 gas 3i 4=5 3 0 0.0 4 0.5 1.0 1.5 2.0 2.5 ENTROPIA (KCAL/KG °C) M. Gambini, M. Vellini – Advanced Energy Systems 3 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 G.I.ST. Cycle Profili di temperatura nel separatore 800 comb. 750 CLP CHP 700 aria 650 TEMPERATURA (°C) 600 1A IC 1 CC1 CC2 0A 550 500 2 6 400 350 TMP1 THP miscela gassosa 450 2P TMP2 2R 6S RH in parallelo 300 250 SEP generazione di vapore ipercritico 200 6R 150 condensazione acqua 100 5 gas 50 4 0 0 10 20 30 40 50 60 70 80 90 100 CALORE SCAMBIATO (%) M. Gambini, M. Vellini – Advanced Energy Systems 3 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Study of unconventional components SEPARATOR Study of the thermodynamic process (cooling of wet gas), development of a proper numerical model m g i m vi (i) , p vi (i) , pgi (i) , TMi (i) SEP m r(i-1) m r(i) Tri(i-1) Tri (i) Tru(i-1) Tru (i) m r(i +1) Tru (i +1) Tri (i +1) m g (i) m vu (i) m c (i-1) , p t (i-1) , Tcm(i-1) vi m vu m c m m c (i) , p t (i) , Tcm(i) p vu (i) , p gu (i) TMu (i) m c (i +1) , p t (i +1) , Tcm(i +1) r H ru H ri m vi m g H Mi m vu m g H Mu m c H cm m h M TM Tc + dmc h io Tc Tr dS h M TM Tc + k G M v p v pc hio Tc Tr M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Study of unconventional components for AMC WET GAS EXPANSION Study of the thermodynamic process (wet gas expansion), development of a proper numerical model sat. gas non in scala T gas saturo TSG gas secco p1 T1 p1g 1g 1 T2’ T2 vapore + acqua 2g’ p2 2’ 2 A B 1v=1s p2g p2g’ S D M. Gambini, M. Vellini – Advanced Energy Systems 2s’ 2v’ 2v 2g C 2a’ D’ Sg F F’ E Sv PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 Study of advanced components 4 5 5 1 1 6 4 6 3 aria ossigeno prodotto ossigeno (crude) azoto liquido azoto gassoso aria ossigeno prodotto ossigeno (crude) azoto liquido azoto (waste) azoto prodotto punto 1 2 3 4 5 6 3 2 T p m (°C) (bar) (kg/kgaria) N2 Composizione (% vol.) O2 Ar 35 -174 -179 32 32 32 5,7 5,2 5,1 1,05 1,05 1,05 0,9995 0,4524 0,3866 0,2400 0,6055 0,1500 78,11 58,34 99,87 1,13 99,91 98,95 20,96 40,00 0,00 95,00 0,02 0,75 0,93 1,66 0,13 3,87 0,07 0,30 2 Fase L=0% L=100% L=100% L=0% L=0% L=0% punto 1 2 3 4 5 6 T p m (°C) (bar) (kg/kgaria) N2 Composizione (% vol.) O2 Ar 35 -174 -179 33 33 33 5,7 5,2 5,1 84 1,05 21 0,4712 0,3810 0,0960 0,2059 0,5987 0,1950 78,11 61,24 99,00 1,66 94,34 99,00 20,96 37,29 0,73 95,02 5,23 0,73 0,93 1,47 0,27 3,32 0,43 0,27 Fase L=0% L=100% L=100% L=0% L=0% L=0% In questo caso l’ossigeno separato viene consegnato a 84 bar e temperatura ambiente ossia in condizioni supercritiche (pcO2=50,4 bar e TcO2=-118,6°C) e l’azoto a 21 bar e temperatura ambiente (pcN2=33,9 bar, TcN2=-147°C) allo stato gassoso. M. Gambini, M. Vellini – Advanced Energy Systems -110 PhD of Industrial Engineering - Research Activity on Energy -140 Università di Roma “Tor Vergata” Rome, 17 October, 2014 -170 Study of advanced components -200 0 10 20 30 40 50 60 70 80 90 100 Q (%) aria O 2, N 2 40 40 a) compressione esterna b) compressione interna 10 10 -20 -20 -50 -80 T (°C) T (°C) -50 -110 -80 -110 cambiamento di fase ossigeno lungo l’isobara ipercritica -140 -140 -170 -170 cambiamento di fase azoto -200 0 10 20 30 40 50 60 70 80 90 100 -200 0 10 20 30 40 50 Q (%) Q (%) aria O 2, N 2 M. Gambini, M. Vellini – Advanced Energy Systems 60 70 80 90 100 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 Study of advanced components OTM technology is based on ceramic materials which can rapidly transport oxygen ions at 800 - 1000°C. pressurized air feed O2 ion-transport membrane ions O- O2 e -- O2 O2 ions O- O2 O2 O2 O2 jO2 e -- O2 recombined oxygen retentate RT i pO2 , f ln 2 16 F L pO2 , p permeate O2 O low pressure, high purity oxygen 2 nOout2 , p nOin2 , p nOin2 , f The fraction of oxygen that a OTM system recovers from a given flow rate of feed air can be adjusted by varying one of the following parameters (assuming that membrane composition and thickness are fixed): • feed air pressure (↑pf ↑ ηO2) • membrane temperature (↑T ↑σ ↑ ηO2) • permeate suction pressure (↓pp ↑ ηO2) • membrane area (↑A ↑ ηO2) M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 Study of advanced components Formulation of mathematical problem element 1 2 3 k k+1 ... ... element k n k- retentate feed sweep permeate Hf k- 1 2 H k-1 f T fk Q k H kj 1 H p 2 H kp T k p k+ 1 2 k+ 1 2 Hf Hp H fk H k+1 p x Δlk b) a) A one-dimensional model has been set up in Matlab. During each step mass and heat transfer across the membrane are solved. Our scope is evaluating membrane area, considering the separation efficiency as an input data. If N is the number of control volumes chosen and nO2,f is the oxygen molar flow at feed inlet, the amount of oxygen permeated through each control volume is given by: nin nOperm 2 O2 O2 , f N Membrane area required in each control volume is related to oxygen flow through the membrane by means of the local permeation rate jO2: perm O2 n A j k k O2 k RT k i pO2 , f A ln 16 F 2 L pOk 2 , p k M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Study of advanced components M. Gambini, M. Vellini – Advanced Energy Systems Rome, 17 October, 2014 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Study of advanced components air air to HRSG syngas to HRSG syngas OTM permeate syngas sweep boost compressor recuperator syngas permeate M. Gambini, M. Vellini – Advanced Energy Systems OTM sweep Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 REFERENCE POWER PLANTS CH4 0.0215 40.0 15.0 567.2 QCOAL=1448 kJ/kgair Waux=81.36 kJ/kgair 1.0 15 1.01 294.5 1.0 398.3 15.2 691.6 C cc m [kg/kg] T [°C] p [bar] h [kJ/kg] 1.0215 1250 14.71 1857 T GASIFICATION ISLAND m [kg/kgair] T [°C] p [bar] h [kJ/kg] 1.0 439.8 18.6 736.6 1.0974 1250 18.0 1778 C.C. 1.0215 630.1 1.07 1081 W = 608 kJ/kg air Qf = 1079 kJ/kgair = 56.35 % 0.1517 565 30. 3602 0.1263 565 140 3498 STHP 1.0215 90.0 1.01 475.8 0.1688 32.94 5.2 138.4 WGT=418.6 kJ/kgair C Wnet=658.2 kJ/kgair T 1.0974 595.8 to the HRSG 1.07 976.6 Q1 Q2 Qexhaust 0.2157 565 30 3602 WSC=320.9 kJ/kgair STMP-LP 0.1263 0.0171 349.3 224.6 31.3 4.05 3113 2912 HRSG 3LR 1.0 15 1.01 294.5 0.1688 32.9 0.05 2416 0.1688 32.9 0.05 137.8 HRSG 3LR 0.1749 565 140 3498 STHP STIP-LP 0.2375 32.9 0.05 2417 0.02178 225 4.0 2912 0.2375 32.94 5.2 138.4 M. Gambini, M. Vellini – Advanced Energy Systems 0.2375 32.91 0.05 137.8 η = 45.46% PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 REFERENCE POWER PLANT: IGCC coal 2 - water COAL TREATMENT WATER HEATING 3 1 - oxidizer GASIFIER SYNGAS COOLING slag Q1 W 4 5 Q2 water Q SYNGAS PURIFICATION 6 - syngas Coal gasification island is composed of: • coal treatment plant, • gasifier • syngas cooling and cleaning The syngas is then burned in the gas turbine combustor H2S 397 451 373 357 200 1330 200 Q1 50 Q2 596 94 Qexhaust 565 335 RH 343 SH HP 343 VAP HP 232 ECO HP 50 379 200 440 In order to use profitably heat from gasification island, more steam is produced by using Q1 and Q2. The optimal integration between gasification island and power section is developed by using the calculation model SuperTarget6, which performs the Pinch Technology 565 411 565 387 243 199 304 159 94 387 565 343 343 333 333 277 239 239 277 239 229 229 174 225 147 137 225 147 137 M. Gambini, M. Vellini – Advanced Energy Systems 59 SH MP 239 VAP MP 138 ECO MP 147 SH LP 147 VAP LP 33 ECO Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 EXHAUST GAS TREATMENT (chemical absorption) Chemical absorption CO2 gases (low CO2) W CO2_RS lean solvent QCO2_RS It is the most suitable method for CO2 separation when carbon dioxide has a low concentration (515% by volume) in a gaseous stream at low pressure It consists of two steps: exhaust gases lean/rich exchanger • absorption of CO2 by chemical solvent at low temperature (40-65°C); • recovery of CO2 from the chemical solvent by using low grade heat, (100-150°C). rich solvent CO2 REMOVAL SECTION (CO2_RS) QCO2_LS Liquefaction and dehydration CO2 liquid W CO2_LS CO2 LIQUEFACTION SECTION (CO2_LS) • compression is carried out in various steps by alternately compressing and cooling; • final cooling reaches a temperature below the CO2 critic temperature. M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 HYDROGEN PRODUCTION BY METHANE DECARBONIZATION (partial oxidation) Qng natural gas QSH air 1 natural gas HEATING water 2 air COMPRESSION REACTOR superheated steam GENERATION 3 SYNGAS COOLING Q1 4 SHIFT REACTORS QCO2_LS CO2 COMPRESSION 5 Q2 SYNGAS COOLING Q3 6 Q 7 SYNGAS PURIFICATION water 8 QCO2_RS It consists of several steps: Fig. 5 – Natural gas decarbonisation (based on methane partial oxidation) • partial oxidation: methane, air and steam are introduced into a catalytic air-blown partial oxidation reactor where different chemical reactions take place: partial and total oxidation together with steam and CO2 reforming of methane; • shift reaction: converts CO to H2 in order to produce a hydrogen-rich fuel gas; this reaction is exothermic and is accomplished in two stages; • fuel gas purification: the CO2 must be separated by a chemical process that consists of two steps: • absorption of CO2 at low temperature by a proper solvent recovery of CO2 by using heat (to break the chemical bonds) CO2 liquefaction: it is performed in various steps by compressing and cooling alternately M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 HYDROGEN PRODUCTION BY METHANE DECARBONIZATION (steam methane reforming) Qng natural gas water QSH 1 2 9 natural gas HEATING superheated steam GENERATION REFORMER QREF oxidizer 3 QCO2_LS CO2 COMPRESSION SYNGAS COOLING Q1 4 SHIFT REACTORS 5 Q2 SYNGAS COOLING Q3 6 Q 7 water SYNGAS PURIFICATION 8 QCO2_RS hydrogen rich furel gas It consists of several steps: • steam methane reforming: methane and steam are introduced into a reformer where the endothermic steam methane reforming reaction takes place; external heat, needed to drive the reaction, can be provided by the combustion between a proper oxidizer and the final fuel; • shift reaction: convert CO to H2 in order to produce a hydrogen-rich fuel gas; this reaction is exothermic and is accomplished in two stages; • fuel gas purification: the CO2 must be separated by a chemical process that consists of two steps: • absorption of CO2 at low temperature by a proper solvent recovery of CO2 by using heat (to break the chemical bonds) CO2 liquefaction: it is performed in various steps by compressing and cooling alternately M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 HYDROGEN PRODUCTION BY COAL GASIFICATION (TEXACO TECHNOLOGY) Q4 2 water COAL WATER HEATING AND STEAM PRODUCTION COAL TREATMENT oxidizer CO2 LIQUEFACTION coal-water slurry 1 3 GASIFIER W 9 8 SYNGAS COOLING Q1 4 SHIFT REACTORS 5 SYNGAS COOLING AND PURIFICATION Q2 6 CO2 REMOVAL 7 Q3 water and H2S slag It consists of several steps: • gasification: coal-water slurry and oxygen react chemically in order to form a syngas which is composed of CO and H2 mainly. Some chemical reactions are exothermic and provide heat to drive the endothermic ones; • shift reaction: convert CO to H2 in order to produce a hydrogen-rich fuel gas; this reaction is exothermic and is accomplished in two stages; • fuel gas purification: the CO2 must be separated by a physical process that consists of two steps: • absorption of CO2 at high pressure by a proper solvent recovery of CO2 by lowering the pressure of the rich solvent CO2 liquefaction: it is performed in various steps by compressing and cooling alternately M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 INTEGRATION OF REFERENCE POWER PLANTS AND EXHAUST GAS TREATMENT SECTION WGT=418.6 kJ/kgair QCOAL=1448 kJ/kgair WSC=242.8 kJ/kgair WGT=380.6 kJ/kgair WSC=196.6 kJ/kgair Waux=81.36 kJ/kgair C.C. CO2 liquid GASIFICATION SECTION Wnet=526.2 kJ/kgair Waux=24.50 kJ/kgair η = 36.34% C T CO2=0.08911 kg/kWh CO2_LP C.C. CO2 liquid Waux=53.95 kJ/kgair incondensables C to CO2_RP T CO2_LP steam from ST incondensables Q1 Q2 Qexhaust CO2_RP STHP CO2 free gases satured water to HRSG to CO2_RP STIP-LP steam from ST HRSG 3LR CO2_RP STHP CO2 free gases satured water to HRSG exhaust gases Wnet=546.9 kJ/kgair exhaust gases η = 50.67% CO2=0.03910 kg/kWh H2 O H2 O M. Gambini, M. Vellini – Advanced Energy Systems HRSG 3LR STIP-LP Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy INTEGRATION OF AMC PLANT AND EXHAUST GAS TREATMENT SECTION fuel 58 air C cc2 HPT ST CO2 LP LPT HRSG 1L - RH Electric efficiency (LHV), % cc1 CO2 liquid Rome, 17 October, 2014 56 54 AMC 52 CC 50 48 46 AMC CC 44 CO2 RP SEP 42 0,040 0,041 0,353 CO2 emissions (kg/kWh) vent to atmosphere H2O excess The performance of AMC is very interesting: • an efficiency over 2 points higher than CC • a CO2 emission of about 0.04 kg/kWh M. Gambini, M. Vellini – Advanced Energy Systems 0,355 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 INTEGRATION OF REFERENCE POWER PLANT AND FOSSIL FUEL DECARBONIZATION SECTION (POX) 686 power section work balance (kJ/kgair) production section required work (kJ/kgair) W CO2_RS+CO2_LS W C_GT W syn_GT W T_GT W p_SC W T_SC W power section 10.12 68.9 445.2 W air_compr_POX W aux 79.02 14.2 973.9 fuel heat input (kJ/kgair) Q fuel 1502 4.8 269.7 CO2 emission (kg/kgair) mCO2 (produced) 0.0834 0.0725 767.8 mCO2 (liquefied) mCO2 (e_CC) 0.0110 overall performance Net work (kJ/kgair) 688.8 Overall efficiency, % specific CO2 emission (kg/kWh) 45.86 0.0573 587 400 400 980 Q1 275 275 275 Q2 162 142 200 465 381 376 304 271 266 203 157 151 142 Q3 86 Q exhaust 90.5 86 584 565 15 Q ng 70 147 565 565 335 RH 565 565 343 SH_HP 343 VAP_HP 565 343 343 343 232 333 ECO_HP 333 280 238 SH_MP 238 VAP_MP 280 238 238 238 225 147 SH_LP 140 ECO_MP 147 VAP_LP 225 228 228 147 147 147 147 137 33 ECO 137 The best power plant performance is attained when all the possible heat, discharged by the hydrogen production plant, is profitably used: • all heat loads (Q1, Q2, Q3) of the production plant can be put in the thermodynamic cycle in order to increase steam production • steam, for the reactor and the CO2 removal plant, is extracted at the suitable pressures from the steam turbines M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 INTEGRATION OF REFERENCE POWER PLANT AND FOSSIL FUEL DECARBONIZATION SECTION (SMR) exhaust gases, at the gas turbine exit, are used in the reformer as oxidizer (they contain enough oxygen to do the combustion and they are also rather hot) hydrogen rich fuel fuel to drive the reforming reaction is part of the total hydrogen rich fuel gas, the other part goes into the combustion chambers of the power plants cc air C steam to H2 produc tion plant T H2 PRODUCTION PLANT CH4 details in fig. 4 ST HRSG 3L + RH exhaust gas fuel at the reformer exit, before shift reactors, is used to heat the mixture steam-methane before reformer inlet steam for reforming and CO2 removal is extracted at 4 bars in the steam section of the power plant steam for the reforming reaction is laminated until to the atmospheric pressure and mixed with natural gas Q3 is used to heat water from environmental condition up to return condensate condition M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 INTEGRATION OF REFERENCE POWER PLANT AND FOSSIL FUEL DECARBONIZATION SECTION (SMR) CC power plant work balance (kJ/kgair) W ST 161.7 CO2, e m=0.01105 kg/kg air CC POWER PLANT W net=493.9 kJ/kg exhaust gases m=1.016 kg/kg W H2 purification gaseous CO2 W CO2 liquefaction hydrogen rich fuel exhaust gases to HRSG H2 purification (shift reactions H2 production (reforming) superheated steam from ST QCH4=1121.4 kJ/kg CO2 liquefaction + CO2 removal) condensate to HRSG methane m=0.02241 kg/kg steam from ST m=0.0355 kg/kg CO2, l m=0.05059 kg/kg W CO2_RS 5.56 WT 811.7 W CO2_LS 17.71 23.27 WC 401.1 Total electric requirement W syn 47.52 Net work output 516.9 fuel mass (kg/kg) mfuel_cc 0.02043 CC power plant mfuel_ref 0.00539 heat balance (kJ/kg) inlet Qa 294.5 Qfuel (HHV) 1628 mCH4 fuel heat (kJ/kg) QCH4 (LHV) (at the global plant inlet) 0.0224 outlet QHRSG+COND 1121.4 807.5 CO2 emission (kg/kg) mCO2 (produced) 0.06164 QREF 288.9 mCO2 (liquefied) 0.05059 QCO2 255.5 mCO2 (e_CC) 0.01105 Qlosses water m=0.0695 kg/kg H2 production plant works (kJ/kg) 53.8 overall performace OVERALL EFFICIENCY, % specific CO2 emission (kg/kWh) the consumption of hydrogen rich fuel in the reformer is over 20% overall efficiency is 44.02% CO2 emission is 0.0806 kg/kWh M. Gambini, M. Vellini – Advanced Energy Systems 44.02 0.0806 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 INTEGRATION OF REFERENCE POWER PLANT AND FOSSIL FUEL DECARBONIZATION SECTION (CG) QCOAL=1508 kJ/kgair Waux=116.8 kJ/kgair COAL DECARBONIZATION SECTION 436 379 350 1330 350 Q1 275 Q2 175 Q3 584 96 Qexhaust 565 329 RH 343 SH HP 275 275 275 m [kg/kgCOAL] T [°C] p [bar] h [kJ/kg] 275 Wnet=572.0 kJ/kgair 1.0 439.8 18.6 736.6 1.028 1250 18.0 1951 η = 37.93% CO2=0.1127 kg/kWh 264 175 366 275 381 288 229 370 320 194 96 C.C. 1.0 15 1.01 294.5 WGT=411.1 kJ/kgair 565 359 565 C T 565 343 Q1 Q2 Q3 Qexhaust HRSG 3LR 1.028 583.7 1.07 1102 to the shift reactors 0.1843 565 30 3602 0.1823 565 140 3498 0.04957 438.1 60 3275 343 to the HRSG 333 280 WSC=277.7 kJ/kgair 239 326 266 333 280 229 STHP 0.1327 349.3 31.2 3113 0.2527 29.54 5.2 124.2 STIP-LP 0.2031 32.9 0.05 2417 0.01877 225 4.0 2912 0.2527 29.51 0.05 123.6 0.04957 15.0 1.03 63 225 147 137 343 VAP HP 232 ECO HP 239 266 239 239 229 162 225 147 SH MP 239 VAP MP 138 ECO MP 147 SH LP 147 VAP LP 33 ECO 137 The best power plant performance is attained when all the possible heat, discharged by the hydrogen production plant, is profitably used: • all heat loads (Q1, Q2, Q3) of the production plant can be put in the thermodynamic cycle in order to increase steam production • steam, for the reactor and the CO2 removal plant, is extracted at the suitable pressures from the steam turbines • warm water, to prepare water-coal slurry is generated by the intercooling heat of oxygen compression M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 TECHNICAL COMPARISON: overall efficiency (exhaust gas treatment vs fossil fuel decarbonization) 70 CO2 emission (%) (kg/kWh) CC (CH4) 607.9 56.34 0.3513 IGCC (coal) 658.2 45.46 0.7124 exhaust gas treatment CC - R 546.9 50.67 0.03910 IGCC - R 526.2 36.34 0.08911 fossil fuel decarbonization CC - POX 688.8 45.86 0.0573 CC - SMR 516.9 44.02 0.0806 CC - CG 572.0 37.93 0.1117 W (kJ/kgair) 60 CC CC-R Overall efficiency (%) 50 CC-POX IGCC CC-SMR IGCC-R 40 CC-CG 30 20 10 0 CC • • IGCC when coal is used, the exhaust gas treatment (IGCC-R) penalizes plant performance very much, while energy results are better when coal decarbonization is performed: the specific work reduction is about 13% for the coal decarbonisation and about 20% for the exhaust gas treatment and overall efficiency decreases of about 7.5 percentage points for the CC-CG and over 9 percentage points for the IGCC-R; when natural gas is used, the exhaust gas treatment is the best solution in order to obtain low CO2 emission and good performance (CC-R): efficiency reduction of about 5.5 percentage points. Vice versa, natural gas decarbonization is a very penalizing system to reduce CO2 emissions M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 TECHNICAL COMPARISON: specific emissions (exhaust gas treatment vs fossil fuel decarbonization) 0,8 IGCC 0,7 CO2 specific emission rate (kg/kWh) CO2 emission (%) (kg/kWh) CC (CH4) 607.9 56.34 0.3513 IGCC (coal) 658.2 45.46 0.7124 exhaust gas treatment CC - R 546.9 50.67 0.03910 IGCC - R 526.2 36.34 0.08911 fossil fuel decarbonization CC - POX 688.8 45.86 0.0573 CC - SMR 516.9 44.02 0.0806 CC - CG 572.0 37.93 0.1117 W (kJ/kgair) 0,6 0,5 0,4 CC 0,3 0,2 CC-R 0,1 IGCC-R CC-CG CC-SMR CC-POX 0 CC • • coal IGCC the CC-R stands out because it exhibits the highest net efficiency and thus the lowest final specific CO2 emission the CC-CG and the IGCC-R are the worst power plants because they have the lowest net efficiency, are fed by the most poor fuel and thus they have the highest final specific CO2 emission fuel decarbonization natural gas M. Gambini, M. Vellini – Advanced Energy Systems exhaust gas treatment Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 ECONOMIC COMPARISON: kWh cost increase (exhaust gas treatment vs fossil fuel decarbonization) 50 Electricity production cost increase (%) 45 CC-SMR IGCC-R 40 CC-POX 35 CC-CG 30 25 20 CC-R 15 10 5 0 • coal: the economic penalizations are similar between the two CO2 emission abetment methodologies: 41.5% for the IGCC-R and 34% for the CC-CG. Coal decarbonization seems to have major potential; • natural gas: the economic penalizations are very moderate only for the exhaust gas treatment (the kWh cost increase is about 18%). This result depends on the high overall efficiency of this solution and on the small increase of the total capital cost. The natural gas decarbonization (CC-POX and CC-SMR) shows similar increases (33.6% and 41.5% respectively) in comparison with coal decarbonization. In fact, even if the total capital costs become very high, the good overall efficiencies allow a positive limitation in the kWh cost increase M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 FINAL COMPARISONS (exhaust gas treatment vs fossil fuel decarbonization) • in order to reduce CO2 emissions when coal is used, the coal decarbonization must be implemented: in this case it is possible to attain a global efficiency of about 38% a specific CO2 emission of 0.1117 kg/kWh an increase of kWh cost of about 34% • vice versa, in order to reduce CO2 emissions when natural gas is used, the exhaust gas treatment must be implemented: in this case it is possible to attain a global efficiency of about 50.7% a specific CO2 emission of 0.0391 kg/kWh an increase of kWh cost of about 18% M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 EFFECTS OF FUEL AND OXIDIZER SWITCHING IN COMBINED CYCLES Using oxygen instead of air and hydrogen instead of natural gas the first consequence is a very high (and inadmissible) oxygen excess in the exhaust gases in order to obtain a fixed TIT (b15 and TIT=1250°C, the final oxygen fraction is over 87% by mass! ) A possible idea for reducing oxygen excess could be the subdivision of the total expansion and the addition of working fluid reheat between two consecutive expansions (like depicted in figure) H2 Also in this way, it is not possible to limit properly the oxygen fraction at the plant discharge and, even if it could happen, there would be another problem: the working fluid, composed mainly of steam, is discharged into the environment at the HRSG exit and thus there is a great thermal loss related to this steam, discharged at ambient pressure. O2 cci cc1 T1 ccn Ti Tn ST HRSG 3L+RH exhaust gas M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 EFFECTS OF FUEL AND OXIDIZER SWITCHING IN STEAM TURBINE TECHNOLOGY CH4 cc1 air C This is the AMC layout. Starting from the scheme it is possible to understand, qualitatively, the main modifications correlated to a change in the oxidizer and in the fuel: limit the oxygen excess by steam injection in the combustion chamber working fluid composed mainly of H2O cc2 HPT ST LPT HRSG 1L RH exhaust gas H2 O excess it could be interesting to study the working fluid expansion until to pressures, typical of the conventional steam cycle. using hydrogen as fuel and oxygen as oxidizer, the thermodynamic solution is an internal combustion steam cycle (ICSC) where H2O (steam) plays a role of inert in the H2-O2 combustion. M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 H2/O2 CYCLES: first reference case H2 O2 2 3 cc1 5 1 12 ST 10 cc2 6 4 HPT 9 a fuel compression section with intercooling; an oxidizer compression section with intercooling; two gas turbines; in the MPT the working fluid is composed mainly of steam; a steam turbine where there is the steam expansion before its injection in the combustion chamber; a heat recovery steam generator for the steam generation and steam reheating; an atmospheric separator in order to obtain the water separation and its recovery MPT 7 11 8 M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 H2/O2 CYCLES: first reference case performance O2 1.0 15 1.01 262.5 1.0 360.6 33.8 594.5 0.0601 280 31.3 6644 2 cc1 1 12 2.455 500 33.8 3451 ST 2.455 565 294 3346 10 2.455 268 36.7 2884 m [kg/kg] T [°C] p [bar] h [kJ/kg] 0.1012 15 1.01 3343 H2 3 3.515 777 2.1 3615 4 3.515 1350 30.4 4919 5 cc2 6 11 4 1400 3.556 1350 2.02 5293 MPT HPT 3.556 1200 1.07 4912 1600 0.0411 240 5.64 6587 7 6 1200 Temperature (°C) LHV = 52.1 MJ/kg HHV = 61.3 MJ/kg 7 1000 800 5 10 600 12 400 W= 5865 kJ/kg = 50,6 % 11 200 2.455 42.8 346 209 8 9 9 8 0 1.10 97.6 1.01 2182 0 2 6 Entropy (kJ/kg/K) 0.01 40. 1.01 167 b=30 TIT=1350°C 4 W=5865 kJ/kg =50.6% M. Gambini, M. Vellini – Advanced Energy Systems 8 10 12 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 H2/O2 CYCLES: second reference case H2 This is the new layout: O2 2 3 cc1 5 1 12 ST 11 4 cc2 6 HPT 11' MPT 7 there will not be water separation in the last HRSG section (SEP) there will be another steam turbine, LPT there will be a “conventional” condenser where all the steam will condense: after, part of the water is sent into the HRSG and part is discharged into the environment LPT 9 8 10 M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 H2/O2 CYCLES: second reference case LHV = 52.1 MJ/kg HHV = 61.3 MJ/kg 1.0 15 1.01 262.5 1800 1.0 361.5 77.5 594.5 0.0765 228 71.8 6259 2 3 3.170 1129 7.4 4511 cc1 1 12 ST 2.094 565 294 3346 11 2.094 370 84.1 3043 4 3.170 1700 2.094 69.6 500 5918 77.4 3401 5 0.0480 228 17.4 600 11' 6 1400 cc2 3.218 1700 7.2 6418 6 HPT 3.218 1220 1.07 5127 4 1600 Temperature (°C) O2 m [kg/kg] T [°C] p [bar] h [kJ/kg] 0.1245 15 1.01 3343 H2 MPT 7 7 1200 5 1000 800 11 600 12 LPT 3.218 206 1.01 2837 9 3.2182 32.55 0.051 2423 b=70 TIT=1700°C 11' 8 200 8 10 10 W= 8834 kJ/kg = 62,5 % 400 0 0 2.094 36.6 346 184 2 4 6 Entropy (kJ/kg/K) W=8834 kJ/kg =62.5% M. Gambini, M. Vellini – Advanced Energy Systems 8 10 12 PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 H2/O2 CYCLE POWER PLANTS: overall performance evaluation fossil fuel • • air H2 PRODUCTION PLANT O2 PRODUCTION PLANT WO2_ASU O2 H2 CO2 • Waux H2 O2 2 3 cc1 5 1 12 ST 11 4 cc2 6 HPT 11' MPT Wnet 7 LPT The main inlet are air and fossil fuel The emission outlet is located in the H2 production plant (it is liquid CO2 and gaseous CO2 only for the reforming) and in the power section (the syngas is not pure hydrogen) The integration between the three systems is very simple: • oxygen flow from ASU to power section and H2 production plant (for gasification) • hydrogen flow from H2 production plant to power section • cycle work from power section to production plants in order to satisfy all mechanical auxiliaries. 9 8 Wnet cycle 10 ηcycle msyngas H isyngas CO2 Two performance parameters are defined: ηoverall Wnet mfuel Hifuel M. Gambini, M. Vellini – Advanced Energy Systems cycle efficiency overall efficiency Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 H2/O2 CYCLE POWER PLANTS: overall results FIRST REFERENCE CASE SECOND REFERENCE CASE p1=30 bars p1=47 bars p1=70 bars p1=30 bar p1=47 bar p1=70 bar cycle overall cycle overall cycle overall cycle overall cycle overall cycle overall TIT=1350°C TIT=1500°C TIT=1700°C • • • G R G R G R 52.76 49.16 56.89 52.55 60.29 55.99 24.56 19.32 27.47 21.08 29.88 22.85 54.18 50.24 58.42 53.59 62.01 57.19 25.56 19.88 28.55 21.61 31.01 23.46 55.05 50.96 59.35 54.20 63.05 57.92 26.10 20.25 29.13 21.92 31.74 23.84 61.41 57.85 65.22 60.96 30.64 23.80 33.33 25.40 62.65 58.72 66.59 61.78 31.53 24.25 34.31 25.83 63.40 59.29 67.45 62.27 31.97 24.54 34.83 26.08 cycle efficiencies of power plants, coupled with coal gasification, are always greater than those of power plants, coupled with steam-methane reforming, because the first syngas is pressurized for the first reference case, cycle efficiencies attain a mean value of about 58%. The overall efficiencies are very low, especially those coupled with the steam methane reforming: the mean values are about 21% and over 28% for H2/O2 cycle power plants based on steam methane reforming and coal gasification respectively. for the second reference case, cycle efficiencies attain a mean value of about 64%. The overall efficiencies are very low, especially those coupled with the steam methane reforming: the mean values are about 25% and 33% for H2/O2 cycle power plants based on steam methane reforming and coal gasification respectively. M. Gambini, M. Vellini – Advanced Energy Systems PhD of Industrial Engineering - Research Activity on Energy Università di Roma “Tor Vergata” Rome, 17 October, 2014 Current research projects air separation unit gasification island HT shift gasifier D C quench ash coal LT shift B gasification island power island and oxygen production air HT shift gasifier D C saturator water A liquefied CO2 booster quench to Claus recuperator ash HRSG B A coal LT shift M1 B C D to H2S stripper power island H2S and CO2 purification island IGCCCryo-ASU Electric power (MW e ) Coal handling, milling and slurry pumps Slag handling Gasification island process pumps Air separation unit N2 compressor O2 compressor Syngas expander Selexol plant auxiliaries CO2 compressors Gas turbine Booster compressor Steam cycle Overall performance Heat input, LHV (MWth) Net electric power (MWe) Net LHV efficiency (%) M2 IGCCOTM saturator water -1.7 -0.6 -1.1 -33.9 -20.6 7.9 -8.3 -15.1 244.5 117.3 800.0 288.5 36.07 -1.7 -0.6 -1.1 -13.3 7.9 -8.3 -15.1 216.7 -6.9 119.1 800.0 296.9 37.12 A liquefied CO2 to Claus HRSG A B C D to H2S stripper H2S and CO2 purification island M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Current research projects M. Gambini, M. Vellini – Advanced Energy Systems Rome, 17 October, 2014 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Current research projects M. Gambini, M. Vellini – Advanced Energy Systems Rome, 17 October, 2014 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Current research projects air-combustion (refrence case) CASE ASU oxycombustion OTM sweep 72,1 10,0 60,0 0,515 0,1912 80,0 0,0957 75,0 587,8 175,0 473,5 318,6 12,3 4,9 206,6 16,0 2,7 258,8 13,0 65,6 34,5 34,5 34,5 Main operating parameters air flow pressure (OTM), bar OTM efficiency (%) mass ratio OTM (sweep/feed) average permeation rate (mol/sm2 ) flue gas recirculation (%) Power section - Electric power (MW) steam turbines vitiated air expander compressors air (FB) oxygen recycled flue gas air (OTM) steam cycle pumps 430,9 437,5 OTM no sweep 40,0 75,0 3,8 0,7 1,9 12,1 Power plant - Electric power (MW) Oxygen production CO 2 compression NET ELECTRIC POWER OUTPUT 400,5 307,7 482,1 465,0 Coal LHV thermal input (MW) Natural gas LHV thermal input (MW) 890,6 890,6 890,6 401,8 890,6 326,1 NET ELECTRIC EFFICIENCY (%) 44,97 34,55 37,30 38,22 Specific CO2 emission (kg/kWh) 0,7327 0,0000 0,1665 0,1401 M. Gambini, M. Vellini – Advanced Energy Systems Rome, 17 October, 2014 Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Thank you for your attention M. Gambini, M. Vellini – Advanced Energy Systems Università di Roma “Tor Vergata” PhD of Industrial Engineering - Research Activity on Energy Rome, 17 October, 2014 Study of unconventional components TURBINA A GAS SATURO D’ACQUA SEPARATORE D’ACQUA analisi termodinamica del processo di raffreddamento di un gas saturo; sviluppo di calcolo, sua • analisi termodinamica del processo di espansione di un gas saturo; modello di • sviluppo di un modello di validazione e calcolo in sede limite e reale un e sua applicazione. applicazione. sat. gas SEP TSG M. Gambini, M. Vellini – Advanced Energy Systems