Cost of energy analysis of integrated gasification combined cycle (IGCC) power plant with respect to CO2 capture ratio under climate change scenarios

This paper presents the results of the cost of energy (COE) analysis of an integrated gasification combined cycle (IGCC) power plant with respect to CO₂ capture ratio under the climate change scenarios. To obtain process data for a COE analysis, simulation models of IGCC power plants and an IGCC with carbon capture and sequestration (CCS) power plant, developed by the United States Department of Energy (DOE) and National Energy Technology Laboratory (NETL), have been adopted and simulated using Aspen Plus. The concept of 20-year levelized cost of energy (LCOE), and the climate change scenarios suggested by International Energy Agency (IEA) are also adopted to compare the COE of IGCC power plants with respect to CO₂ capture ratio more realistically. Since previous studies did not consider fuel price and CO₂ price changes, the reliability of previous results of LCOE is not good enough to be accepted for an economic comparison of IGCC power plants with respect to CO₂ capture ratio. In this study, LCOEs which consider price changes of fuel and CO₂ with respect to the climate change scenarios are proposed in order to increase the reliability of an economic comparison. And the results of proposed LCOEs of an IGCC without CCS power plant and IGCC with CCS (30%, 50%, 70% and 90% capture-mole basis- of CO₂ in syngas stream) power plants are presented.     

Techno-economic optimization of IGCC integrated with utility system for CO2 emissions reduction—Maximum power production in IGCC

Environmental legislation, with its increasing pressure on the energy sector to control greenhouse gases, is a driving force to reduce CO₂ emissions. In this paper, pre-combustion CO₂ capture through integration of a site utility system with an integrated gasification combined cycle (IGCC) is investigated as an option to provide a compressed CO₂-rich stream from a process site for sequestration. This work presents a two-step procedure for integration and optimization of a site utility system with an IGCC plant: (i) screening and optimization of IGCC plant performance parameters; (ii) integration and optimization of the utility system of the site with the IGCC plant. In the first step, an optimization approach applies the results of screening studies based on rigorous simulation of the IGCC. Having fixed the inlet fuel flow rate, the IGCC design parameters (including oxygen consumption, diluent flow rate and turbine exit pressure) are optimized for maximum power generation. Energy flows between the IGCC and CO₂ compression train are considered. In the second step, the economic and operating performance of the utility system integrated with the IGCC plant are modeled and optimized for minimum operating cost to find the most appropriate level of integration. In a case study illustrating the approach, 94% of the fuel is gasified; additional power generation offsets the operating costs of pre-combustion CO₂ capture.     

Performance analysis of integrated biomass gasification fuel cell (BGFC) and biomass gasification combined cycle (BGCC) systems

Biomass gasification processes are more commonly integrated to gas turbine based combined heat and power (CHP) generation systems. However, efficiency can be greatly enhanced by the use of more advanced power generation technology such as solid oxide fuel cells (SOFC). The key objective of this work is to develop systematic site-wide process integration strategies, based on detailed process simulation in Aspen Plus, in view to improve heat recovery including waste heat, energy efficiency and cleaner operation, of biomass gasification fuel cell (BGFC) systems. The BGFC system considers integration of the exhaust gas as a source of steam and unreacted fuel from the SOFC to the steam gasifier, utilising biomass volatilised gases and tars, which is separately carried out from the combustion of the remaining char of the biomass in the presence of depleted air from the SOFC. The high grade process heat is utilised into direct heating of the process streams, e.g. heating of the syngas feed to the SOFC after cooling, condensation and ultra-cleaning with the Rectisol^® process, using the hot product gas from the steam gasifier and heating of air to the SOFC using exhaust gas from the char combustor. The medium to low grade process heat is extracted into excess steam and hot water generation from the BGFC site. This study presents a comprehensive comparison of energetic and emission performances between BGFC and biomass gasification combined cycle (BGCC) systems, based on a 4th generation biomass waste resource, straws. The former integrated system provides as much as twice the power, than the latter. Furthermore, the performance of the integrated BGFC system is thoroughly analysed for a range of power generations, ～100–997 kW. Increasing power generation from a BGFC system decreases its power generation efficiency (69–63%), while increasing CHP generation efficiency (80–85%).     

Optimization of energy usage for fleet‐wide power generating system under carbon mitigation options

This article presents a fleet‐wide model for energy planning that can be used to determine the optimal structure necessary to meet a given CO₂ reduction target while maintaining or enhancing power to the grid. The model incorporates power generation as well as CO₂ emissions from a fleet of generating stations (hydroelectric, fossil fuel, nuclear, and wind). The model is formulated as a mixed integer program and is used to optimize an existing fleet as well as recommend new additional generating stations, carbon capture and storage, and retrofit actions to meet a CO₂ reduction target and electricity demand at a minimum overall cost. The model was applied to the energy supply system operated by Ontario power generation (OPG) for the province of Ontario, Canada. In 2002, OPG operated 79 electricity generating stations; 5 are fueled with coal (with a total of 23 boilers), 1 by natural gas (4 boilers), 3 nuclear, 69 hydroelectric and 1 wind turbine generating a total of 115.8 TWh. No CO₂ capture process existed at any OPG power plant; about 36.7 million tonnes of CO₂ was emitted in 2002, mainly from fossil fuel power plants. Four electricity demand scenarios were considered over a span of 10 years and for each case the size of new power generation capacity with and without capture was obtained. Six supplemental electricity generating technologies have been allowed for: subcritical pulverized coal‐fired (PC), PC with carbon capture (PC+CCS), integrated gasification combined cycle (IGCC), IGCC with carbon capture (IGCC+CCS), natural gas combined cycle (NGCC), and NGCC with carbon capture (NGCC+CCS). The optimization results showed that fuel balancing alone can contribute to the reduction of CO₂ emissions by only 3% and a slight, 1.6%, reduction in the cost of electricity compared to a calculated base case. It was found that a 20% CO₂ reduction at current electricity demand could be achieved by implementing fuel balancing and switching 8 out of 23 coal‐fired boilers to natural gas. However, as demand increases, more coal‐fired boilers needed to be switched to natural gas as well as the building of new NGCC and NGCC+CCS for replacing the aging coal‐fired power plants. To achieve a 40% CO₂ reduction at 1.0% demand growth rate, four new plants (2 NGCC, 2 NGCC+CCS) as well as carbon capture processes needed to be built. If greater than 60% CO₂ reductions are required, NGCC, NGCC+CCS, and IGCC+CCS power plants needed to be put online in addition to carbon capture processes on coal‐fired power plants. The volatility of natural gas prices was found to have a significant impact on the optimal CO₂ mitigation strategy and on the cost of electricity generation. Increasing the natural gas prices resulted in early aggressive CO₂ mitigation strategies especially at higher growth rate demands. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

廊坊IGCC热电联供项目脱碳示范技术方案研究

廊坊IGCC热电联供项目主体方案分别对大同混煤采用干法粉煤气化技术(以Shell为代表)和湿法水煤浆气化技术(以GE为代表)进行了研究。技术方案研究重点对这2种气化技术的CCS系统配置进行研究,推荐了小规模试验时合适的抽气点。对Shell废锅流程合成气和GE废锅流程合成气所适用的变换工艺进行了分析,推荐了合适的变换工艺为低汽气比变换技术和NHD脱硫脱碳净化技术。最后对所设计的IGCC+CCS流程进行了建模分析,研究发现IGCC电厂采用CCS系统后对效率的影响是:脱碳后Shell方案比GE方案发电效率、供电效率的降低幅度大,但其发电效率和供电效率仍然高于GE方案,只是高的幅度要低于不脱碳时的数值。     

Modeling,optimization, and cost analysis of an IGCC plant with a membrane reactor for carbon capture

This article presents a theoretical study on the integration of a membrane reactor (MR) for carbon capture into an integrated gasification combined cycle (IGCC) plant. First‐principles, simplified systems‐level models for the individual IGCC units and the MR are introduced for their subsequent plantwide integration. The integrated plant model is then used for simulation studies that assume different MR characteristics. Using this model, an optimization problem is formulated to analyze the MR effects when adding it to the IGCC plant, while satisfying all of the process constraints in streams and performance variables. The solution of this optimization problem indicates improvements in the original case studies, including capital cost savings as high as $18 million for the optimal case under nominal process conditions. To determine the cost implications of inserting the MR into the IGCC plant, a differential cost analysis is performed taking into account major plant capital and operating costs. This analysis considers the same amount of coal and power generation for cases with and without the MR. The results of this analysis based on a present value of annuity calculation show break even costs for the MR within the feasible range for membrane fabrication, even for short membrane lifetimes. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1568–1580, 2016     

浅谈IGCC联产甲醇中变换与燃气热回收工艺的选择

IGCC联产甲醇工艺为国家“863”项目示范装置,采用新型多喷嘴气化炉,煤处理量为1000t/d,配套240kt／a甲醇和71．8MW发电装置。自2005年10月投产以来运行十分稳定,其中变换与燃气热回收工艺的合理选择。对全系统的经济、稳定运行及优化IGCC联合循环发电的排放指标起到了非常重要的的作用。     

Effect of air separation unit integration on integrated gasification combined cycle performance and NO<Subscript>x</Subscript> emission characteristics

Thermodynamic simulation method is developed and applied to analyze the performance and the NO_x emission characteristics of the IGCC (Integrated Gasification Combined Cycle) power plants coupled with ASU (Air Separation Unit). Simulations on IGCC power plants are made through combining the chemical process models for coal gasification and gas clean-up and the thermodynamic combined cycle model with NO_x prediction capability. With coal as feedstock of IGCC, the present study investigates and compares the power output, the overall efficiency and the NO_x emission characteristics of various IGCC plants at different ASU integration conditions in order to give the design criteria for efficient and environmental friendly IGCC configuration.     

Optimization of IGCC processes with reduced order CFD models

Integrated gasification combined cycle (IGCC) plants have significant advantages for efficient power generation with carbon capture. Moreover, with the development of accurate CFD models for gasification and combined cycle combustion, key units of these processes can now be modeled more accurately. However, the integration of CFD models within steady-state process simulators, and subsequent optimization of the integrated system, still presents significant challenges. This study describes the development and demonstration of a reduced order modeling (ROM) framework for these tasks. The approach builds on the concepts of co-simulation and ROM development for process units described in earlier studies. Here we show how the ROMs derived from both gasification and combustion units can be integrated within an equation-oriented simulation environment for the overall optimization of an IGCC process. In addition to a systematic approach to ROM development, the approach includes validation tasks for the CFD model as well as closed-loop tests for the integrated flowsheet. This approach allows the application of equation-based nonlinear programming algorithms and leads to fast optimization of CFD-based process flowsheets. The approach is illustrated on two flowsheets based on IGCC technology.     

Rigorous-simulation pinch-technology refined approach for process synthesis of the water-gas shift reaction system in an IGCC process with carbon capture

Integrated gasification combined cycle (IGCC) technology is becoming increasingly more competitive among advanced power generation systems suitable for carbon capture. As an emerging technology, many different IGCC process configurations have been heuristically proposed to meet even more aggressive economic and environmental goals. One attractive design combines gasification with a water-gas shift (WGS) reaction system, pressure swing adsorption, and chemical-looping combustion (CLC) for CO₂ removal prior to feeding the fuel gas to the combined cycle for power production. The WGS reaction step is required to convert CO to CO₂ and the extent of conversion is determined by the degree of carbon capture required in the CLC step. As a first towards optimizing the overall energy efficiency of this IGCC process, we apply heat exchanger network synthesis (HENS) to the WGS reaction system. This particular part of the process was chosen because of its evident integration potential (steam required for the WGS reactions can be generated by recovering energy released by the same reactions) and the influence of some of the gasifier parameters (temperature and pressure) on its performance and on all the subsequent parts of the process. After generating alternative designs using Aspen Energy Analyzer (AEA), the HENS problem was formulated in the sequential-modular Aspen Plus simulator using a process superstructure approach and solved by mixed integer nonlinear programming (MINLP) algorithms. The HENS capability is implemented as CAPE-OPEN (CO) compliant unit operation and makes use of MINLP algorithms, namely Generalized Bender's Decomposition (GBD), Outer Approximation (OA), Equality Relaxation (ER), Augmented Penalty (AP), and Simulated Annealing (SA). This MINLP-based HENS was used in the CO-compliant Aspen Plus simulator to obtain a design for the WGS reaction system that provided a cost of energy for the IGCC system with CO₂ capture that was 28% lower than the base case.     

Optimal design and integration of an air separation unit (ASU) for an integrated gasification combined cycle (IGCC) power plant with CO2 capture

The air separation unit (ASU) plays a key role in improving the efficiency, availability, and operability of an oxygen-fed integrated gasification combined cycle (IGCC) power plant. An optimal integration between the ASU and the balance of the plant, especially the gasifier and the gas turbine (GT), has significant potential for enhancing the overall plant efficiency. Considering the higher operating pressure of the GT, an elevated-pressure air separation unit (EP-ASU) is usually favored instead of the conventional low-pressure air separation units (LP-ASU). In addition, a pumped liquid oxygen (PLOX) cycle is usually chosen if the operating pressure of the gasifier is high. A PLOX cycle helps to improve plant safety and availability and to decrease the capital cost by reducing the size of the oxygen compressor or by eliminating it completely. However, the refrigeration lost in withdrawn liquid oxygen must be efficiently recovered. This paper considers five different configurations of an ASU with PLOX cycle and compares their power consumptions with an EP-ASU with a traditional gaseous oxygen (GOX) cycle. The study shows that an optimally designed EP-ASU with a PLOX cycle can have similar power consumption to that of an EP-ASU with GOX cycle in the case of 100% nitrogen integration. In the case of an IGCC with pre-combustion CO₂ capture, the lower heating value (LHV) of the shifted syngas, both on a mass and volumetric basis, is in between the LHV of the unshifted syngas from an IGCC plant and the LHV of natural gas, for which the GTs are generally designed. The optimal air integration in the case of a shifted syngas is found to be much lower than that of an unshifted syngas. This paper concurs with the existing literature that the optimal integration occurs when air extracted from the GT can be replaced with the nitrogen from the ASU without exceeding mass/volumetric flow limitations of the GT. Considering nitrogen and air integration between the ASU and the GT, this paper compares the power savings in an LP-ASU with a PLOX cycle to the power savings in an EP-ASU with GOX cycle and EP-ASU with PLOX cycle. The results show that an LP-ASU with a PLOX cycle has less power consumption if the nitrogen integration levels are less than 50-60%. In addition, a study is carried out by varying the concentration of nitrogen and steam in the fuel diluents to the GT while the NOx level was maintained constant. The study shows that when the nitrogen injection rate exceeds 50%, an EP-ASU with a PLOX cycle is a better option than an LP-ASU with a PLOX cycle. This paper shows that an optimal design and integration of an ASU with the balance of the plant can help to increase the net power generation from an IGCC plant with CO₂ capture.     

Optimization of a High Temperature PEMFC micro‐CHP System by Formulation and Application of a Process Integration Methodology

A 1 kWe micro combined heat and power (CHP) system based on high temperature proton exchange membrane fuel cell (PEMFC) technology is modeled and optimized by formulation and application of a process integration methodology. The system can provide heat and electricity for a single‐family household. It consists of a fuel cell stack, a fuel processing subsystem, heat exchangers, and balance‐of‐plant components. The optimization methodology involves system optimization attempting to maximize the net electrical efficiency, and then by use of a mixed integer nonlinear programming (MINLP) problem formulation, the heat exchange network (HEN) annual cost is minimized. The results show the high potential of the proposed model since high efficiencies are accomplished. The net electrical efficiency and total system efficiency, based on lower heating value (LHV), are 35.2% and 91.1%, respectively. The minimized total annual cost of the HEN is $8,147 year^–1.     

Process synthesis and economics of combined biomethanol and CHP energy production derived from biomass wastes

BACKGROUND: This paper reports on process synthesis and economics of combined methanol and CHP (combined heat and power) energy production from crude biooil, waste glycerol produced in biodiesel factories and biomass wastes using integrated reactor design for hydrogen rich syngas. This new process consists of three process steps: (a) pyrolysis of organic waste material to produce biooil, char and pyrogas; (b) steam assisted hydrogasification of the crude glycerol wastes, biooil mixed with pyrogas for hydrogen rich gas; and (c) a low temperature methanol synthesis process. The H₂‐rich gas remaining after methanol synthesis is recycled back to the pyrolysis reactor, the catalytic hydro‐gasification process and the heat recovery steam generator (HRSG). RESULTS: The breakeven price of the Hbiomethanol process yields positive net financial NPV and IRR above 600 USD per tonne. The total capital cost for a small‐scale methanol plant of capacity 2 tonne h^?1 combined with a cogeneration plant of capacity 2 MWe power is estimated to be 170.5 million USD. CONCLUSION: Recycling gas allows the methanol synthesis reactor to perform at a relatively lower pressure than conventionally while the plant still maintains a high methanol yield. The integrated hydrogasification reactor and energy recovery design process minimizes heat loss and increases the process thermal efficiency. The Hbiomethanol process can convert any condensed carbonaceous material and liquid wastes, to produce methanol and CHP. Copyright © 2012 Society of Chemical Industry     

Product diversification to enhance economic viability of second generation ethanol production in Brazil: The case of the sugar and ethanol joint production

Commercial simulator Aspen Plus^® was used to simulate the conventional processes of the autonomous distillery producing ethanol and the joint production of sugar and ethanol. Changes in conventional processes were evaluated to increase electricity and second generation ethanol production using bagasse fine fraction composed by parenchyma cells (P-fraction). The evaluated processes were thermal and water integrated. The results indicated that the integration of the second generation process to the conventional processes was possible after thermal and water integration. The economic analysis showed that the second generation process integrated to the joint production presented lower payback time, 2.3 years, in comparison with this process integrated to the autonomous distillery, 4.7 years. Due to the high enzyme costs, the cases without second generation ethanol production presented higher economic viability. Product diversification, as sugar and ethanol production in the same site, lowered the impact of enzymes cost on the payback time of second generation process, showing that the integration of the second generation ethanol production process to the conventional sugar production process could be a step to cellulosic ethanol production feasibility in sugarcane mills.     

基于有机朗肯循环的混合二甲苯MVR热泵精馏工艺

常规机械蒸气再压缩（MVR）热泵精馏分离混合二甲苯工艺,存在压缩机电耗较大及塔顶压缩蒸气的显热未被利用等问题。有机朗肯循环（ORC）发电技术则可以将低温余热转化为电能以供压缩机使用,由此提出了ORC发电技术耦合MVR热泵和带乏汽回热循环（EGC）的ORC发电技术耦合MVR热泵两种精馏工艺应用于本体系的分离研究。以年总费用（TAC）和能耗为分离工艺的评价指标,系统净输出功和循环热效率作为ORC系统的评价指标,对以上两种耦合精馏工艺进行模拟与优化,并与常规MVR热泵精馏工艺进行比较与分析。研究结果表明,ORC发电技术耦合MVR热泵精馏工艺和带EGC的ORC发电技术耦合MVR热泵精馏工艺较常规MVR热泵精馏工艺均具有一定的节能和经济优势,可分别减少能耗9.64%和9.89%,节省TAC 3.19%和3.50%。     

基于液态空气储能技术的新型整体煤气化联合循环系统分析

液态空气储能技术是一种环境适应性好、容量大的电能存储技术,将液态空气储能技术与整体煤气化联合循环发电系统(IGCC)相结合,利用液空储能技术获取燃气轮机发电所需的高压空气,提高燃气轮机的出功,同时提高IGCC发电系统调峰、调频的能力,提高电能质量。本文从热力学角度出发,对该新型整体煤气化联合循环发电系统进行分析计算,建立系统物质和能量平衡,计算了系统的主要工艺参数。结果表明,净功率为150MW的液态空气-整体煤气化联合循环发电系统,燃气轮机净功率为95.9MW,汽轮机功率为53.9MW,系统热效率为52.8%;相同参数下未应用液态空气储能技术的整体煤气化联合循环发电机组功率为151.4MW,而传统简单循环燃气发电机组热效率仅为35.8%。     

Techno-economic assessment of providing control energy reserves with a biogas plant

Grid stability is being challenged by the increasing integration of power plants with volatile power generation into the energy system. Power supply fluctuations must be compensated by energy system flexibility. The storability of the energy carrier enables biogas plants to generate power flexibly. In this study, the technical and economic effects of providing positive secondary control energy reserves with an Austrian biogas plant were assessed. The plant’s main focus lies in biomethane production with the option of heat and power generation through combined heat and power (CHP) units. A detailed simulation model of the investigated biogas plant was developed, which is presented in this work. Ex-post simulations of one year of flexible plant operation were conducted with this model. The findings show that the installed biogas storage capacity is sufficient to provide control energy reserves while simultaneously producing biomethane. Profitability of providing control energy reserves largely depends on the prices at the control energy market and on CHP unit start-up costs. A cost efficiency analysis demonstrated that investing in a hot water tank with a volume of 5 m³ for short-term heat storage turned out to be economically viable.

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Linking renewables and fossil fuels with carbon capture via energy storage for a sustainable energy future

Renewable energy sources and low-carbon power generation systems with carbon capture and storage (CCS) are expected to be key contributors towards the decarbonisation of the energy sector and to ensure sustainable energy supply in the future. However, the variable nature of wind and solar power generation systems may affect the operation of the electricity system grid. Deployment of energy storage is expected to increase grid stability and renewable energy utilisation. The power sector of the future, therefore, needs to seek a synergy between renewable energy sources and low-carbon fossil fuel power generation. This can be achieved via wide deployment of CCS linked with energy storage. Interestingly, recent progress in both the CCS and energy storage fields reveals that technologies such as calcium looping are technically viable and promising options in both cases. Novel integrated systems can be achieved by integrating these applications into CCS with inherent energy storage capacity, as well as linking other CCS technologies with renewable energy sources via energy storage technologies, which will maximise the profit from electricity production, mitigate efficiency and economic penalties related to CCS, and improve renewable energy utilisation.     

热电联产机组热电解耦技术对比分析

增加热电联产机组运行的灵活性可以提高可再生能源利用率,减小“弃风”和“弃光”率,然而对于灵活性改造技术的对比分析研究相对较少。本文基于Ebsilon建立了600MW案例机组的热力学模型,采用Matlab调用模拟数据构建了该机组的能耗模型。基于此模型对比分析了热泵、电锅炉、蓄热罐及采用汽轮机本体改造等热电解耦技术对机组供热可行域及可行域内机组热力性能的影响规律。研究结果表明,采用热电解耦技术可以扩大机组的供热可行域,当机组热负荷为500MW时,采用热电解耦技术后,机组最小调峰能力由大到小排列为：电锅炉>低压缸光轴运行>低压缸零出力>压缩式热泵>蓄热罐。但电锅炉的能量利用率与?效率在所有热电解耦技术中最低。综合对比分析,在热电联产机组中采用压缩式热泵或热泵与蓄热罐耦合运行是一种节能的热电解耦方式。     

基于质子交换膜燃料电池的微型天然气热电联产研发进展

基于质子交换膜燃料电池(PEMFC)的微型天然气热电联产系统有着广阔的市场发展前景。这种系统将千瓦级天然气制氢、燃料电池发电及余热利用有机的结合在一起,可以将天然气的一部分高品质的化学能通过氢气这个中间介质转化为电能,其余的低品位的能量用于采暖及生活热水供应,可有效提高系统的可用能利用程度,实现天然气这种清洁能源的"温度对口、梯级利用"。介绍了微型燃料电池热电联产系统的技术路线,并对国内外微型制氢技术的研发及热电联产系统的产业化状况进行了介绍和分析。