A comparison of electricity and hydrogen production systems with CO2 capture and storage. Part A: Review and selection of promising conversion and capture technologies

We performed a consistent comparison of state-of-the-art and advanced electricity and hydrogen production technologies with CO₂ capture using coal and natural gas, inspired by the large number of studies, of which the results can in fact not be compared due to specific assumptions made. After literature review, a standardisation and selection exercise has been performed to get figures on conversion efficiency, energy production costs and CO₂ avoidance costs of different technologies, the main parameters for comparison. On the short term, electricity can be produced with 85–90% CO₂ capture by means of NGCC and PC with chemical absorption and IGCC with physical absorption at 4.7–6.9 €ct/kWh, assuming a coal and natural gas price of 1.7 and 4.7 €/GJ. CO₂ avoidance costs are between 15 and 50 €/t CO₂ for IGCC and NGCC, respectively. On the longer term, both improvements in existing conversion and capture technologies are foreseen as well as new power cycles integrating advanced turbines, fuel cells and novel (high-temperature) separation technologies. Electricity production costs might be reduced to 4.5–5.3 €ct/kWh with advanced technologies. However, no clear ranking can be made due to large uncertainties pertaining to investment and O&M costs. Hydrogen production is more attractive for low-cost CO₂ capture than electricity production. Costs of large-scale hydrogen production by means of steam methane reforming and coal gasification with CO₂ capture from the shifted syngas are estimated at 9.5 and 7 €/GJ, respectively. Advanced autothermal reforming and coal gasification deploying ion transport membranes might further reduce production costs to 8.1 and 6.4 €/GJ. Membrane reformers enable small-scale hydrogen production at nearly 17 €/GJ with relatively low-cost CO₂ capture.     

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

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

Integrated gasification combined cycle and carbon capture: A risky option to mitigate CO2 emissions of coal-fired power plants

The power sectors of many big economies still rely on coal-fired plants and emit huge amounts of carbon dioxide. Emerging countries like Brazil, China and South Africa plan to expand the use of coal-fired thermal plants in the next decade. Integrated gasification combined cycle (IGCC) is an innovative technology that facilitates the implementation of carbon capture (CC). The present work analyzes the maturity and costs of the IGCC technology, with and without CC, and assesses the effect of the technology risk on its economic viability. Findings show that the inclusion of the risk in the economic analysis of IGCC plants raises the cost of CO₂ avoided from 36 US$/t_CO2 to 106 US$/t_CO2 in the case of Shell Gasifiers and from 39 US$/t_CO2 to 112 US$/t_CO2 in the case of GE Gasifiers. Thus, the introduction of IGCC with CC on a wider scale faces huge uncertainties. The feasibility of these plants will rely heavily on the overcoming of the technology risk. Besides, its implementation in the short run will depend on government incentives to bear with the additional cost incurred in the first-generation plants.     

Pre-combustion, post-combustion and oxy-combustion in thermal power plant for CO2 capture

This paper presents a summary of technical-economic studies. It allows evaluating, in the French context, the production cost of electricity derived from coal and gas power plants with the capture of CO₂, and the cost per tonne of CO₂ avoided. Three systems were studied: an Integrated Gasification Combined Cycle (IGCC), a conventional combustion of Pulverized Coal (PC) and a Natural Gas Combined Cycle (NGCC). Three main methods were envisaged for the capture of CO₂: pre-combustion, post-combustion and oxy-combustion.For the IGCC, two gasification types have been studied: a current technology based on gasification of dry coal at 27 bars (Shell or GE/Texaco radiant type) integrated into a classical combined cycle providing 320 MWe, and a future technology (planned for about 2015–2020) based on gasification of a coal–water mixture (slurry) that can be compressed to 64 bars (GE/Texaco slurry type) integrated into an advanced combined cycle (type H with steam cooling of the combustion turbine blades) producing a gross power output of 1200 MWe.     

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

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

CO2 capture study in advanced integrated gasification combined cycle

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

Comparative assessment of CO2 capture technologies for carbon-intensive industrial processes

This article presents a consistent techno-economic assessment and comparison of CO₂ capture technologies for key industrial sectors (iron and steel, cement, petroleum refineries and petrochemicals). The assessment is based on an extensive literature review, covering studies from both industries and academia. Key parameters, e.g., capacity factor (91-97%), energy prices (natural gas: 8 €₂₀₀₇/GJ, coal: 2.5 €₂₀₀₇/GJ, grid electricity: 55 €/MWh), interest rate (10%), economic plant lifetime (20 years), CO₂ compression pressure (110 bar), and grid electricity CO₂ intensity (400 g/kWh), were standardized to enable a fair comparison of technologies. The analysis focuses on the changes in energy, CO₂ emissions and material flows, due to the deployment of CO₂ capture technologies. CO₂ capture technologies are categorized into short-mid term (ST/MT) and long term (LT) technologies. The findings of this study identified a large number of technologies under development, but it is too soon to identify which technologies would become dominant in the future. Moreover, a good integration of industrial plants and power plants is essential for cost-effective CO₂ capture because CO₂ capture may increase the industrial onsite electricity production significantly.For the iron and steel sector, 40-65 €/tCO₂ avoided may be achieved in the ST/MT, depending on the ironmaking process and the CO₂ capture technique. Advanced LT CO₂ capture technologies for the blast furnace based process may not offer significant advantages over conventional ones (30-55 €/tCO₂ avoided). Rather than the performance of CO₂ capture technique itself, low-cost CO₂ emissions reduction comes from good integration of CO₂ capture to the ironmaking process. Advanced smelting reduction with integrated CO₂ capture may enable lower steel production cost and lower CO₂ emissions than the blast furnace based process, i.e., negative CO₂ mitigation cost. For the cement sector, post-combustion capture appears to be the only commercial technology in the ST/MT and the costs are above 65 €/tCO₂ avoided. In the LT, a number of technologies may enable 25-55 €/tCO₂ avoided. The findings also indicate that, in some cases, partial CO₂ capture may have comparative advantages. For the refining and petrochemical sectors, oxyfuel capture was found to be more economical than others at 50-60 €/tCO₂ avoided in ST/MT and about 30 €/tCO₂ avoided in the LT. However, oxyfuel retrofit of furnaces and heaters may be more complicated than that of boilers.Crude estimates of technical potentials for global CO₂ emissions reduction for 2030 were made for the industrial processes investigated with the ST/MT technologies. They amount up to about 4 Gt/yr: 1 Gt/yr for the iron and steel sector, about 2 Gt/yr for the cement sector, and 1 Gt/yr for petroleum refineries. The actual deployment level would be much lower due to various constraints, about 0.8 Gt/yr, in a stringent emissions reduction scenario.     

Combined production of hydrogen and power from heavy oil gasification: Pinch analysis,thermodynamic and economic evaluations

Integrated Gasification Combined Cycle (IGCC) represents a commercially proven technology available for the combined production of hydrogen and electricity power from coal and heavy residue oils. When associated with CO₂ capture and sequestration facilities, the IGCC plant gives an answer to the search for a clean and environmentally compatible use of high sulphur and heavy metal contents fuels, the possibility of installing large size plants for competitive electric power and hydrogen production, and a low cost of CO₂ avoidance.     

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

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

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

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

Cost of energy and environmental policy in Portuguese CO2 abatement—scenario analysis to 2020

This paper quantifies the contribution of Portuguese energy policies for total and marginal abatement costs (MAC) for CO₂ emissions for 2020. The TIMES_PT optimisation model was used to derive MAC curves from a set of policy scenarios including one or more of the following policies: ban on nuclear power; ban on new coal power plants without carbon sequestration and storage; incentives to natural gas power plants; and a cap on biomass use. The different MAC shows the policies’ effects in the potential for CO₂ abatement. In 2020, in the most encompassing policy scenario, with all current and planned policies, is possible to abate only up to +35% of 1990 emissions at a cost below 23 € t/CO₂. In the more flexible policy scenarios, it is possible to abate up to −10% of 1990 emissions below the same cost. The total energy system costs are 10–13% higher if all policies are implemented—76 to 101 B€—roughly the equivalent to 2.01–2.65% of the 2005 GDP. Thus, from a CO₂ emission mitigation perspective, the existing policies introduce significant inefficiencies, possibly related to other policy goals. The ban on nuclear power is the instrument that has the most significant effect in MAC.     

Effects of supplementary biomass firing on the performance of combined cycle power generation: A comparison between NGCC and IGCC plants

In the present work, effects of biomass supplementary firing on the performance of fossil fuel fired combined cycles have been analyzed. Both natural gas fired combined cycle (NGCC) and integrated coal gasification combined cycle (IGCC) have been considered in the study. The efficiency of the NGCC plant monotonically reduces with the increase in supplementary firing, while for the IGCC plant the maximum plant efficiency occurs at an optimum degree of supplementary firing. This difference in the nature of variation of the efficiency of two plants under the influence of supplementary firing has been critically analyzed in the paper. The ratings of different plant equipments, fuel flow rates and the emission indices of CO₂ from the plants at varying degree of supplementary firing have been evaluated for a net power output of 200 MW. The fraction of total power generated by the bottoming cycle increases with the increase in supplementary firing. However, the decrease in the ratings of gas turbines is much more than the increase in that of the steam turbines due to the low work ratio of the topping cycle. The NGCC plants require less biomass compared to the IGCC under identical condition. A critical degree of supplementary firing has been identified for the slag free operation of the biomass combustor. The performance parameters, equipment ratings and fuel flow rates for no supplementary firing and for the critical degree of supplementary biomass firing have been compared for the NGCC and IGCC plants.     

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

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

Process simulation and integration of IGCC systems for H2/syngas/electricity generation with control on CO2 emissions

IGCC is a pre-combustion technology that can be effectively used to produce both hydrogen and electricity while reducing the greenhouse gas (GHG) emissions. Two process models are developed in Aspen Plus^® software and are compared techno-economically. The conventional design of IGCC process is taken as case 1, whereas, case 2 represents the conceptual design of sequential integration of reforming model with the gasification unit to enhance the syngas yield. The case 2 utilizes the steam generated in the gasification process to sustain the methane reforming process which consequently enhances both the H₂ production capacity and cold gas efficiency. It has been analyzed from results that case 2 can enhance the process performance by 4.77% and economics in terms of cost of electricity by 5.9% compared to the conventional process. However, the utilization of natural gas in the case 2 is considered as a standalone fuel so the process performance of NGCC power plants has been also incorporated to ensure the realistic analysis. The results also showed that case 2 design offers 3.9% higher process performance than the cumulative (IGCC + NGCC) processes, respectively. Moreover, the CO₂ specific emissions and LCOE for the case 2 is also lower than the case.     

Gas hydrate formation process for pre-combustion capture of carbon dioxide

In this study, gas hydrate from CO₂/H₂ gas mixtures with the addition of tetrahydrofuran (THF) was formed in a semi-batch stirred vessel at various pressures and temperatures to investigate the CO₂ separation/recovery properties. This mixture is of interest to CO₂ separation and recovery from Integrated Gasification Combine Cycle (IGCC) power plants. During hydrate formation the gas uptake was determined and composition changes in the gas phase were obtained by gas chromatography. The impact of THF on hydrate formation from the CO₂/H₂ was observed. The addition of THF significantly reduced the equilibrium formation conditions. 1.0 mol% THF was found to be the optimum concentration for CO₂ capture based on kinetic experiments. The present study illustrates the concept and provides thermodynamic and kinetic data for the separation/recovery of CO₂ (pre-combustion capture) from a fuel gas (CO₂/H₂) mixture.     

Industrial test and techno-economic analysis of CO2 capture in Huaneng Beijing coal-fired power station

The first industrial-scale CO₂ capture plant in China has been demonstrated at Huaneng Beijing power plant has shown that this technology is a good option for the capture of CO₂ produced by commercial coal-fired power plants. The commissioning and industrial tests are introduced in this paper. The tests show that in the early stages of the passivation phase, the concentration variations of amine, anti-oxidant and Fe³⁺ are in the normal range, and the main parameters achieve the design value. The efficiency of the CO₂ capture was about 80–85%, and by the end of January 2009 about 900 tons of CO₂ (99.7%) have been captured. The equipment investment and consumptive costs, including steam, power, solution and others, have been analyzed. The results show: the cost of the absorber and the stripper account for about 50% of main equipment; the consumptive cost is about 25.3 US$ per metric tons of CO₂, of which the steam requirement accounts for about 55%; the COE increased by 0.02 US$/kW h and the electricity purchase price increased by 29%.     

CO2 control technology effects on IGCC plant performance and cost

As part of the USDOE's Carbon Sequestration Program, an integrated modeling framework has been developed to evaluate the performance and cost of alternative carbon capture and storage (CCS) technologies for fossil-fueled power plants in the context of multi-pollutant control requirements. This paper uses the newly developed model of an integrated gasification combined cycle (IGCC) plant to analyze the effects of adding CCS to an IGCC system employing a GE quench gasifier with water gas shift reactors and a Selexol system for CO₂ capture. Parameters of interest include the effects on plant performance and cost of varying the CO₂ removal efficiency, the quality and cost of coal, and selected other factors affecting overall plant performance and cost. The stochastic simulation capability of the model is also used to illustrate the effect of uncertainties or variability in key process and cost parameters. The potential for advanced oxygen production and gas turbine technologies to reduce the cost and environmental impacts of IGCC with CCS is also analyzed.     

Natural gas combined cycle with exhaust gas recirculation and CO2 capture at part-load operation

This paper aims to evaluate part-load operation of a natural gas combined cycle (NGCC) power plant with exhaust gas recirculation (EGR) and a CO₂ capture plant. Several studies have demonstrated the feasibility and the advantages of EGR at full load, but operation at part load is also important because it is a common condition when NGCC power plants are being used as backup for renewables. The results of this study show that the number of absorber trains is reduced from 4 to 3 with EGR. The efficiency of the NGCC plant with EGR was 0.5% points higher than a conventional NGCC at full load as a result of a higher CO₂ concentration in the flue gas. However, this efficiency advantage decreased as the load was reduced from 100% to 50%, with both cases presenting the same efficiency at 50% load. This means that there was no benefit from the effect of EGR at lower loads. The efficiency of a NGCC plant with EGR and CO₂ capture configuration decreased from 52.6% to 45.9% when the load was reduced from 100% to 50% compared with a conventional NGCC where the efficiency changed from 52.1% to 45.9%. It was concluded that a NGCC plant with EGR and CO₂ capture is viable, results in lower capital costs due to the smaller number of absorber trains and yields slightly higher efficiencies, for operation at part-load down to 50%.     

Evaluation of power generation schemes based on hydrogen-fuelled combined cycle with carbon capture and storage (CCS)

IGCC is a power generation technology in which the solid feedstock is partially oxidized to produce syngas. In a modified IGCC design for carbon capture, there are several technological options which are evaluated in this paper. The first two options involve pre-combustion arrangements in which syngas is processed, either by shift conversion or chemical looping, to maximise the hydrogen level and to concentrate the carbon species as CO₂. After CO₂ capture by gas-liquid absorption or chemical looping, the hydrogen-rich gas is used for power generation. The third capture option is based on post-combustion arrangement using chemical absorption.Investigated coal-based IGCC case studies produce 400-500 MW net power with more than 90% carbon capture rate. Principal focus of the paper is concentrated on evaluation of key performance indicators for investigated carbon capture options, the influence of various gasifiers on carbon capture process, optimisation of energy efficiency by heat and power integration, quality specification of captured CO₂. The capture option with minimal energy penalty is based on chemical looping, followed by pre-combustion and post-combustion.     

Combined power and hydrogen production from coal. Part B: Comparison between the IGHP and CPH systems

Currently, plants for hydrogen production from coal are based on IGCC (Integrated Gasification Combined Cycle) technologies with CO₂ capture and electrical power is also produced by using the purge gas coming from the hydrogen separation unit as fuel in a gas turbine combined cycle.