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US20130152595A1 - Process for the enhancement of power plant with co2 capture and system for realization of the process - Google Patents

Process for the enhancement of power plant with co2 capture and system for realization of the process Download PDF

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Publication number
US20130152595A1
US20130152595A1 US13/710,951 US201213710951A US2013152595A1 US 20130152595 A1 US20130152595 A1 US 20130152595A1 US 201213710951 A US201213710951 A US 201213710951A US 2013152595 A1 US2013152595 A1 US 2013152595A1
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Prior art keywords
power plant
flue gas
enriched gas
gas stream
unit
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US13/710,951
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Alexander Alekseev
Rob Smith
Ramachandran Krishnamurthy
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Linde GmbH
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Linde GmbH
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Assigned to LINDE AKTIENGESELLSCHAFT reassignment LINDE AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALEKSEEV, ALEXANDER, SMITH, ROB, KRISHNAMURTHY, RAMACHANDRAN
Publication of US20130152595A1 publication Critical patent/US20130152595A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/62—Carbon oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/26—Drying gases or vapours
    • B01D53/265—Drying gases or vapours by refrigeration (condensation)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C9/00—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/007—Supplying oxygen or oxygen-enriched air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2252/00—Absorbents, i.e. solvents and liquid materials for gas absorption
    • B01D2252/20—Organic absorbents
    • B01D2252/204—Amines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/12—Oxygen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/10—Single element gases other than halogens
    • B01D2257/102—Nitrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/50—Carbon oxides
    • B01D2257/504—Carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/02—Other waste gases
    • B01D2258/0283—Flue gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2215/00—Preventing emissions
    • F23J2215/50—Carbon dioxide
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L2900/00—Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/07001—Injecting synthetic air, i.e. a combustion supporting mixture made of pure oxygen and an inert gas, e.g. nitrogen or recycled fumes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
    • Y02C20/00—Capture or disposal of greenhouse gases
    • Y02C20/40—Capture or disposal of greenhouse gases of CO2
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/32—Direct CO2 mitigation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Definitions

  • the present invention generally concerns power plants with CO 2 capture and especially power plants with CO 2 capture for enhanced oil recovery (EOR) purposes.
  • EOR enhanced oil recovery
  • exhaust gas recirculation can be used in fossil-fired power plants to control the production of gaseous emissions, in particular to enrich the CO 2 content of the exhaust gas, reducing or eliminating the need for costly CO 2 capture.
  • the separated CO 2 can be forwarded into storage or used for enhanced oil recovery or other purposes.
  • the oxyfuel-based system has a similar problem, i.e. a large amount of air is required to be treated in the air separation unit for the production of the oxygen that goes into combustion.
  • the system therefore becomes large, possibly requiring a multi-train solution and inefficient.
  • Exhaust gas recirculation has the problem that the oxygen lean recirculation gas, when mixed with incoming ambient air results in a oxygen depleted/CO 2 enriched air stream for the power plant that can affect the output, efficiency, stability and operation of the power plant.
  • the present invention provides improved techniques for CO 2 capture from a power plant and reuse thereof that is an improvement over the techniques known in the prior art.
  • FIG. 1 is a schematic drawing showing a fossil fuel power plant with CO 2 capture according to the invention.
  • FIG. 2 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture according to the invention.
  • FIG. 3 is a schematic drawing showing a fossil fuel fired gas turbine cycle power plant with CO 2 capture according to the invention.
  • FIG. 4 is a schematic drawing showing a fossil fuel fired steam cycle power plant with CO 2 capture according to the invention.
  • FIG. 5 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR according to the invention.
  • FIG. 6 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture, for providing CO 2 , N 2 and CO 2 /N 2 mixtures for EOR according to the invention.
  • FIG. 7 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR, having a direct contact flue gas cooler according to the invention.
  • FIG. 8 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR, having a chilled water direct contact flue gas cooler according to the invention.
  • the present invention provides improved techniques for CO 2 capture from a power plant that is an improvement over the techniques known in the prior art and particularly to CO 2 capture for EOR (Enhanced Oil Recovery) purposes.
  • One goal of the present invention is to create an efficient power plant with CO 2 combustion.
  • the process according to the present invention is based on a combination of the exhaust gas recirculation process, oxy-fuel process and post combustion process (chemical solvent process).
  • a portion of the exhaust gas from the power plant is recirculated to the air inlet and mixed with both incoming ambient air and an oxygen rich gas stream.
  • the oxygen content of the mixed stream is adjusted by addition of the oxygen rich stream that may be provided from an air separation unit, or other appropriate source.
  • This mixture results in a CO 2 enriched flue gas from the power plant that is partly recycled to the power plant with the remainder flowing to the chemical solvent process unit, where the CO 2 is separated.
  • This process of flue gas recycle and oxygen enrichment are used to control the parameters of the combustion process for the power plant and to make the CO 2 separation easier.
  • FIG. 1 is a schematic drawing showing a fossil fuel power plant with CO 2 capture according to the invention.
  • a power plant 100 is fueled by a fossil fuel source 10 that may be a solid, liquid or gaseous source, in addition to air from an air source 20 , and an oxygen rich gas 32 from an air separation unit (ASU) 30 that is supplied by an air source 34 .
  • the oxygen rich gas 32 is preferably 50% to 100% oxygen.
  • the ASU separates the air supplying the oxygen rich gas 32 to the power plant 100 and releasing a waste stream of nitrogen enriched gas 36 .
  • the power plant 100 emits flue gas 42 that is treated in a flue gas treatment unit 40 .
  • the flue gas treatment unit 40 operates to cool the flue gas 42 and to remove water 44 and various waste 46 while emitting a CO 2 enriched gas stream 48 .
  • Part of the CO 2 enriched gas stream 48 is recycled and mixed with the air from the air source 20 and the oxygen rich gas 32 prior to being fed to the power plant 100 .
  • An optional process of heating part of the flue gas 42 in a heater 43 and then mixing the pre-heated gas with the recycled portion of CO 2 enriched gas stream 48 can be employed. This allows for pre-heating of the feed gas to the power plant 100 .
  • the CO 2 enriched gas stream 48 that is not recycled to the power plant 100 is processed for waste removal in a chemical solvent process unit 50 that emits a waste stream 52 and a CO 2 containing gas 54 .
  • the CO 2 containing gas 54 can then be compressed and dried and sent to storage units 60 from which it can be supplied for end user processes 70 .
  • FIG. 2 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture according to the invention.
  • the system shown in FIG. 2 is the same as that shown in FIG. 1 with the exception that the power plant 100 has been replace with a combined gas turbine and steam generator plant.
  • the mixed CO 2 air and oxygen rich gas is delivered to a gas turbine 200 with the flue gas 42 passing through a heat recovery steam generator with rankine cycle 205 prior to the delivery to the flue gas treatment unit 40 .
  • the heat recovery steam generator can optionally be supplied with fossil fuel from the fossil fuel source 10 .
  • the recycle CO 2 stream can be fed directly to the plant 200 without premixing with air or oxygen enriched gas.
  • FIG. 3 is a schematic drawing showing a fossil fuel fired gas turbine cycle power plant with CO 2 capture according to the invention.
  • the system shown in FIG. 3 is the same as that shown in FIG. 1 with the exception that the power plant 100 is more specifically identified as a gas turbine.
  • the mixed CO 2 air and oxygen rich gas is delivered to a gas turbine 300 with the flue gas 42 delivered to the flue gas treatment unit 40 .
  • FIG. 4 is a schematic drawing showing a fossil fuel fired steam cycle power plant with CO 2 capture according to the invention.
  • the system shown in FIG. 4 is the same as that shown in FIG. 1 with the exception that the power plant 100 is more specifically identified as a steam turbine.
  • the mixed CO 2 air and oxygen rich gas is delivered to a steam turbine 400 with the flue gas 42 delivered to the flue gas treatment unit 40 .
  • FIG. 5 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR according to the invention.
  • the system shown in FIG. 5 is the same as that shown in FIG. 2 with the exception that the end user is specifically identified as an EOR.
  • CO 2 62 can be delivered from storage unit 60 to an EOR user 72 .
  • the nitrogen rich gas 36 from the ASU 30 can be delivered to and EOR user 74 .
  • CO 2 62 from the storage unit 60 can be mixed with the nitrogen rich gas 36 from the ASU 30 and delivered as a mixture to an EOR user 76 .
  • FIG. 6 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture, for providing CO 2 , N 2 and CO 2 /N 2 mixtures for EOR according to the invention.
  • the system shown in FIG. 6 is the same as that shown in FIG. 5 with the exception that the CO 2 /N 2 gas mixture is derived in a different manner.
  • part of the recycle CO 2 stream can be treated in oxygen removal unit 600 to remove oxygen and provide a N 2 enriched stream 602 that is then mixed with the CO 2 containing gas 54 to form a CO 2 /N 2 gas mixture that is delivered to storage unit 60 and delivery to EOR user 76 .
  • the oxygen removal unit 600 can be any suitable unit, such as a catalytic de-oxo unit with CH 4 or H 2 from an external source or from reforming of natural gas, or a conventional burner with CH 4 or H 2 .
  • FIG. 7 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR, having a direct contact flue gas cooler according to the invention.
  • the system shown in FIG. 7 is the same as that shown in FIG. 5 with the exception that the flue gas treatment unit has been replaced with a more specific water coolant treatment unit and the chemical solvent process has been more specifically identified as an amine wash plant.
  • the flue gas 42 is treated in water coolant treatment unit 700 to remove water 44 and waste 46 prior to being recycled or further treated in amine wash plant 750 .
  • the ASU 30 can be a cryogenic ASU.
  • FIG. 8 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO 2 capture for EOR, having a chilled water direct contact flue gas cooler according to the invention.
  • the system shown in FIG. 8 is the same as that shown in FIG. 7 with the exception that the water coolant treatment unit is specifically identified as a chilled water direct contact flue gas cooler.
  • the flue gas 42 is treated in chilled water direct contact flue gas cooler 800 to remove water 44 and waste 46 prior to being recycled or further treated in amine wash plant 750 .
  • This system may also employ a cryogenic ASU.
  • the invention offers several advantages.
  • oxygen enriched air from an ASU as part of the recycle feed to the power plant, the CO 2 concentration in the recycle gas is greater than a feed stream because there is less nitrogen in the feed. This makes the power plant more efficient.
  • since less nitrogen is entering the system there is a greater concentration of CO 2 in the flue gas.
  • This makes the chemical solvent treatment process more efficient and increases the efficiency of the whole power plant system.
  • only a fraction of the air required needs to be separated in the air separation unit when operating according to the invention. Therefore the irreversibility caused by the air separation is reduced.
  • the air separation plant can be more compact in the invention because of the reduced air flow requirement and the size of the absorption plant is also reduced because of the lower nitrogen concentration in the flue gas. It is therefore possible for the system of the invention to be used in either a single-train- or double-train solution, which allows for simpler control methodology.
  • the mixed gas provided to the power plant is oxygen enriched and therefore the output, efficiency, stability and operation of the power plant is enhanced.
  • the system of the invention can advantageously be used for retrofitting of existing power plants, because only minor changes are required to the power plant input.

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Abstract

Improved methods and systems for power plants with CO2 capture and especially power plants with CO2 capture for enhanced oil recovery (EOR) purposes.

Description

    FIELD OF THE INVENTION
  • The present invention generally concerns power plants with CO2 capture and especially power plants with CO2 capture for enhanced oil recovery (EOR) purposes.
    • BACKGROUND OF THE INVENTION
  • It is known that power plants for the generation of electrical and thermal energy having gas and/or steam turbines driven by fossil fuels may be equipped with systems based on chemical solvent processes (amines, chilled ammonia and others) for the capture of carbon dioxide (CO2) from the flue gas resulting from the combustion of the fossil fuels; the so called “post combustion carbon capture process”.
  • It is also known that exhaust gas recirculation can be used in fossil-fired power plants to control the production of gaseous emissions, in particular to enrich the CO2 content of the exhaust gas, reducing or eliminating the need for costly CO2 capture.
  • It is also known that an alternative technology is the so called “oxyfuel process” based on combustion of fossil fuels in an oxygen-enriched stream instead of the ambient air (which contains approximately 21% by volume of oxygen only). If nitrogen is removed prior to combustion, the flue gas stream would then have less nitrogen and the concentration of CO2 becomes higher, reducing or eliminating the need for costly CO2 capture.
  • Following any necessary post-treatment, the separated CO2 can be forwarded into storage or used for enhanced oil recovery or other purposes.
  • Further information concerning this technical background can be found in “Developments and innovations in carbon dioxide (CO2) capture and storage technology”; Volume 1; Carbon dioxide (CO2) capture, transport and industrial applications; edited by M. Mercedes Maroto-Valer; Woodhead Publishing Limited, 2010, ISBN 978-1-84569-533-0.
  • In the post-combustion CO2 capture system the whole flue gas flow is processed at low pressure, therefore this system (apparatus, pipelines, etc.) becomes voluminous and expensive. Some vessels can become so large, that the system is not feasible as a one-train solution, therefore several trains working in parallel are required for realization of such a process.
  • One issue with the post-combustion CO2 capture system results from the low CO2 concentration in the flue gas (3-15% depending on the fuel and combustion system). The efficiency of the chemical solvent process plant depends on the CO2 concentration in the flue gas, a low CO2 concentration generally resulting in a low efficiency.
  • The oxyfuel-based system has a similar problem, i.e. a large amount of air is required to be treated in the air separation unit for the production of the oxygen that goes into combustion. The system therefore becomes large, possibly requiring a multi-train solution and inefficient.
  • Exhaust gas recirculation has the problem that the oxygen lean recirculation gas, when mixed with incoming ambient air results in a oxygen depleted/CO2 enriched air stream for the power plant that can affect the output, efficiency, stability and operation of the power plant.
  • For all of the above reasons, there remains a need in the art for improvements to CO2 capture from a power plant.
    • SUMMARY OF THE PRESENT INVENTION
  • The present invention provides improved techniques for CO2 capture from a power plant and reuse thereof that is an improvement over the techniques known in the prior art.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic drawing showing a fossil fuel power plant with CO2 capture according to the invention.
  • FIG. 2 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture according to the invention.
  • FIG. 3 is a schematic drawing showing a fossil fuel fired gas turbine cycle power plant with CO2 capture according to the invention.
  • FIG. 4 is a schematic drawing showing a fossil fuel fired steam cycle power plant with CO2 capture according to the invention.
  • FIG. 5 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR according to the invention.
  • FIG. 6 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture, for providing CO2, N2 and CO2 /N2 mixtures for EOR according to the invention.
  • FIG. 7 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR, having a direct contact flue gas cooler according to the invention.
  • FIG. 8 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR, having a chilled water direct contact flue gas cooler according to the invention.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • The present invention provides improved techniques for CO2 capture from a power plant that is an improvement over the techniques known in the prior art and particularly to CO2 capture for EOR (Enhanced Oil Recovery) purposes. One goal of the present invention is to create an efficient power plant with CO2 combustion.
  • The process according to the present invention is based on a combination of the exhaust gas recirculation process, oxy-fuel process and post combustion process (chemical solvent process). A portion of the exhaust gas from the power plant is recirculated to the air inlet and mixed with both incoming ambient air and an oxygen rich gas stream. The oxygen content of the mixed stream is adjusted by addition of the oxygen rich stream that may be provided from an air separation unit, or other appropriate source. This mixture results in a CO2 enriched flue gas from the power plant that is partly recycled to the power plant with the remainder flowing to the chemical solvent process unit, where the CO2 is separated. This process of flue gas recycle and oxygen enrichment are used to control the parameters of the combustion process for the power plant and to make the CO2 separation easier.
  • The invention will be described in greater detail with reference to the drawing figures, wherein like components are labeled with like reference numerals. In particular, FIG. 1 is a schematic drawing showing a fossil fuel power plant with CO2 capture according to the invention. In FIG. 1, a power plant 100 is fueled by a fossil fuel source 10 that may be a solid, liquid or gaseous source, in addition to air from an air source 20, and an oxygen rich gas 32 from an air separation unit (ASU) 30 that is supplied by an air source 34. The oxygen rich gas 32 is preferably 50% to 100% oxygen. The ASU separates the air supplying the oxygen rich gas 32 to the power plant 100 and releasing a waste stream of nitrogen enriched gas 36. The power plant 100 emits flue gas 42 that is treated in a flue gas treatment unit 40. The flue gas treatment unit 40 operates to cool the flue gas 42 and to remove water 44 and various waste 46 while emitting a CO2 enriched gas stream 48. Part of the CO2 enriched gas stream 48 is recycled and mixed with the air from the air source 20 and the oxygen rich gas 32 prior to being fed to the power plant 100. An optional process of heating part of the flue gas 42 in a heater 43 and then mixing the pre-heated gas with the recycled portion of CO2 enriched gas stream 48 can be employed. This allows for pre-heating of the feed gas to the power plant 100. The CO2 enriched gas stream 48 that is not recycled to the power plant 100 is processed for waste removal in a chemical solvent process unit 50 that emits a waste stream 52 and a CO2 containing gas 54. The CO2 containing gas 54 can then be compressed and dried and sent to storage units 60 from which it can be supplied for end user processes 70.
  • FIG. 2 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture according to the invention. The system shown in FIG. 2 is the same as that shown in FIG. 1 with the exception that the power plant 100 has been replace with a combined gas turbine and steam generator plant. In particular, the mixed CO2 air and oxygen rich gas is delivered to a gas turbine 200 with the flue gas 42 passing through a heat recovery steam generator with rankine cycle 205 prior to the delivery to the flue gas treatment unit 40. The heat recovery steam generator can optionally be supplied with fossil fuel from the fossil fuel source 10. Further, optionally the recycle CO2 stream can be fed directly to the plant 200 without premixing with air or oxygen enriched gas.
  • FIG. 3 is a schematic drawing showing a fossil fuel fired gas turbine cycle power plant with CO2 capture according to the invention. The system shown in FIG. 3 is the same as that shown in FIG. 1 with the exception that the power plant 100 is more specifically identified as a gas turbine. In particular, the mixed CO2 air and oxygen rich gas is delivered to a gas turbine 300 with the flue gas 42 delivered to the flue gas treatment unit 40.
  • FIG. 4 is a schematic drawing showing a fossil fuel fired steam cycle power plant with CO2 capture according to the invention. The system shown in FIG. 4 is the same as that shown in FIG. 1 with the exception that the power plant 100 is more specifically identified as a steam turbine. In particular, the mixed CO2 air and oxygen rich gas is delivered to a steam turbine 400 with the flue gas 42 delivered to the flue gas treatment unit 40.
  • FIG. 5 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR according to the invention. The system shown in FIG. 5 is the same as that shown in FIG. 2 with the exception that the end user is specifically identified as an EOR. In particular, CO 2 62 can be delivered from storage unit 60 to an EOR user 72. Alternatively, the nitrogen rich gas 36 from the ASU 30 can be delivered to and EOR user 74. In a further alternative, CO 2 62 from the storage unit 60 can be mixed with the nitrogen rich gas 36 from the ASU 30 and delivered as a mixture to an EOR user 76.
  • FIG. 6 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture, for providing CO2, N2 and CO2/N2 mixtures for EOR according to the invention. The system shown in FIG. 6 is the same as that shown in FIG. 5 with the exception that the CO2/N2 gas mixture is derived in a different manner. In particular, part of the recycle CO2 stream can be treated in oxygen removal unit 600 to remove oxygen and provide a N2 enriched stream 602 that is then mixed with the CO2 containing gas 54 to form a CO2/N2 gas mixture that is delivered to storage unit 60 and delivery to EOR user 76. The oxygen removal unit 600 can be any suitable unit, such as a catalytic de-oxo unit with CH4 or H2 from an external source or from reforming of natural gas, or a conventional burner with CH4 or H2.
  • FIG. 7 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR, having a direct contact flue gas cooler according to the invention. The system shown in FIG. 7 is the same as that shown in FIG. 5 with the exception that the flue gas treatment unit has been replaced with a more specific water coolant treatment unit and the chemical solvent process has been more specifically identified as an amine wash plant. In particular, the flue gas 42 is treated in water coolant treatment unit 700 to remove water 44 and waste 46 prior to being recycled or further treated in amine wash plant 750. In this system the ASU 30 can be a cryogenic ASU.
  • FIG. 8 is a schematic drawing showing a fossil fuel fired combined cycle power plant with CO2 capture for EOR, having a chilled water direct contact flue gas cooler according to the invention. The system shown in FIG. 8 is the same as that shown in FIG. 7 with the exception that the water coolant treatment unit is specifically identified as a chilled water direct contact flue gas cooler. In particular, the flue gas 42 is treated in chilled water direct contact flue gas cooler 800 to remove water 44 and waste 46 prior to being recycled or further treated in amine wash plant 750. This system may also employ a cryogenic ASU.
  • The invention offers several advantages. By using oxygen enriched air from an ASU as part of the recycle feed to the power plant, the CO2 concentration in the recycle gas is greater than a feed stream because there is less nitrogen in the feed. This makes the power plant more efficient. In addition, since less nitrogen is entering the system, there is a greater concentration of CO2 in the flue gas. This makes the chemical solvent treatment process more efficient and increases the efficiency of the whole power plant system. In addition, only a fraction of the air required needs to be separated in the air separation unit when operating according to the invention. Therefore the irreversibility caused by the air separation is reduced. The air separation plant can be more compact in the invention because of the reduced air flow requirement and the size of the absorption plant is also reduced because of the lower nitrogen concentration in the flue gas. It is therefore possible for the system of the invention to be used in either a single-train- or double-train solution, which allows for simpler control methodology.
  • By using the invention, the mixed gas provided to the power plant is oxygen enriched and therefore the output, efficiency, stability and operation of the power plant is enhanced. Further, the system of the invention can advantageously be used for retrofitting of existing power plants, because only minor changes are required to the power plant input.
  • It is anticipated that other embodiments and variations of the present invention will become readily apparent to the skilled artisan in the light of the foregoing description, and it is intended that such embodiments and variations likewise be included within the scope of the invention as set out in the appended claims.

Claims (23)

What is claimed:
1. A power plant system comprising:
a fossil fueled power plant having an inlet and an exhaust;
a flue gas treatment unit communicating with the exhaust of the power plant;
a recycle line communicating with the flue gas treatment unit and the inlet of the power plant;
an air separation unit communicating with the inlet of the power plant;
an ambient air source communicating with the inlet of the power plant;
wherein at least a portion of a CO2 enriched gas stream from the flue gas treatment unit is mixed with oxygen enriched gas from the air separation unit and ambient air from the ambient air source to form a mixed gas stream that is delivered by the recycle line to the inlet of the power plant.
2. The power plant system of claim 1 wherein the power plant is a power plant for an enhanced oil recovery system.
3. The power plant system of claim 1 wherein the power plant is a gas turbine, a steam generator or a combined gas turbine and steam generator.
4. The power plant system of claim 1 wherein the air separation unit is a cryogenic air separation unit.
5. The power plant system of claim 1 further comprising a heater communicating with the flue gas treatment unit and with the recycle line, for preheating the CO2 enriched gas stream.
6. The power plant system of claim 1 further comprising a chemical processing unit communicating with the flue gas treatment unit wherein the portion of the CO2 enriched gas stream that is not recycled is treated in the chemical processing unit.
7. The power plant system of claim 6 wherein the chemical processing unit is an amine wash unit.
8. The power plant system of claim 1 wherein the flue gas treatment unit is a direct contact flue gas cooler or a chilled water direct contact flue gas cooler.
9. The power plant system of claim 1 wherein the portion of the CO2 enriched gas stream that is not recycled is provided to end users.
10. The power plant system of claim 9 wherein the end user is an enhanced oil recovery operation.
11. The power plant system of claim 1 wherein the air separation unit produces a nitrogen enriched gas stream that may be provided directly to an end user.
12. The power plant system of claim 11 further comprising a mixing unit communicating with the flue gas treatment unit and with the air separation unit wherein the portion of the CO2 enriched gas stream that is not recycled and the nitrogen enriched gas stream from the air separation unit are mixed for supply to end users.
13. A method of enhancing the operation of a power plant comprising:
collecting flue gas from the power plant;
recycling at least a portion of the collected flue gas to the power plant;
mixing the recycled flue gas with air and oxygen enriched gas; and
delivering the mixed gases to the power plant.
14. The method of claim 13 further comprising supplying the oxygen enriched gas from an air separation unit.
15. The method of claim 13 wherein the oxygen enriched gas is from 50% to 100% oxygen.
16. The method of claim 13 further comprising treating the flue gas prior to the step of recycling a portion of the flue gas.
17. The method of claim 16 wherein treating the flue gas comprises processing the flue gas through a direct contact flue gas cooler or through a chilled water direct contact flue gas cooler.
18. The method of claim 13 further comprising delivering the portion of the flue gas that is not recycled to an end user.
19. The method of claim 18 wherein the end user is an enhanced oil recovery operation.
20. The method of claim 13 further comprising
producing a nitrogen enriched gas stream from the air separation unit; and
delivering the nitrogen enriched gas stream to an end user.
21. The method of claim 20 further comprising
mixing the portion of the flue gas that is not recycled with the nitrogen enriched gas stream; and
delivering the mixture to an end user.
22. The method of claim 21 further comprising removing oxygen from the flue gas prior to mixing with the nitrogen enriched gas stream.
23. A method of enhancing the operation of a power plant comprising:
collecting flue gas from the power plant;
recycling at least a portion of the collected flue gas to the power plant; and
delivering air and oxygen enriched gas to the power plant.
US13/710,951 2011-12-20 2012-12-11 Process for the enhancement of power plant with co2 capture and system for realization of the process Abandoned US20130152595A1 (en)

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