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1. Post-Combustion
Introduction 2. Pre-Combustion De-Carbonization (hydrogen)
CO2 capture and geological storage could provide a significant 3. Oxyfuel
GreenHouse Gas (GHG) mitigation option if the cost of
capture can be reduced and the public can be assurethat A process flow diagram (Figure 3) illustrates each capture
geological storage is safe, measureable and verifiable. technology.
The CO2 Capture Project (CCP) is a public/private partnership The four real-life scenarios chosen were:
initiated in 2000 to address the two issues above. Industry
participants are BP, ChevronTexaco, EnCana, Eni, Norsk 1. Distributed Gas Turbines in Alaska, USA.
Hydro, Shell, Statoil and Suncor. Government funding was 2. A Refinery in the UK, Europe.
provided by USA, EU and Norway. Project funding was 3. A Power Station in Norway
$50mm over three years (including cash and in-kind 4. Petroleum Coke Gasification in Canada
contributions). CCP objectives were to:
The first two scenarios exist today; the third and fourth would
• Develop low cost next generation technology, which be new-build. These are described in more detail in Figure 4.
achieves the ability to capture and geologically sequester
from industrial turbines, boilers, heaters, and power For each scenario, the uncontrolled emissions were established
generation systems, which emit CO2. and a CO2 capture plant was designed, engineered and costed
• Determine the key principles and practices to maximize on a consistent basis, using the current Best Available
the volume of CO2, which can be safely sequestered in Technology (BAT). In the case of the first three scenarios,
geologic formations. BAT was assumed to be the Fluor Econamine FGSM process
• Develop procedures and guidelines to monitor and verify and in the case of the petroleum coke gasification, BAT was
storage of CO2 in geologic formations. assumed to be Selexol. This exercise also established (for
• Identify and recommend policies and incentives, which BAT), the volume of CO2 captured and the volume of CO2
may enhance economic viability of CO2 capture and avoided (which takes account of secondary emissions from the
sequestration schemes. capture plant). Obviously, the goal of the project is to
minimize the cost of avoiding CO2 emissions.
The project timeline is shown in Figure 1.
The project organization chart is shown in Figure 2. To facilitate like-for-like comparison, CO2 avoidance costs for
the full-scale facilities were estimated assuming common
Capture Costs location factors (US Gulf Coast) as well as location-specific
The specific objectives for the capture teams were: costs. Costs are expressed in absolute terms as well as unitary
(US$ per tonne CO2 avoided) and incremental electricity cost
(US$/KWhr).
2 SPE 86602
Three separate teams worked on each capture technology and not be cost-effective.
their key findings are outlined below: • In order to use hydrogen as fuel, gas turbines, heaters
and boilers must be modified.
Post-Combustion Technologies
CCP sponsored PCDC R&D focused on two main approaches
Technology Development to reduce cost of CO2 capture:
Four technologies were sponsored: • Combined reaction and separation
1. Electrical Swing Adsorption • Integration and standardisation of hydrogen
2. Cost-Efficient Design and Integration technologies
3. Combination of Kvaerner Membrane Contactor with
the Kansai/Mitsubishi advanced solvent Technology Development
4. Radical Chemistry Combined Reaction and Separation:
• Sorbent based process
Summary of Results • Sorbent enhanced reaction
Post-Combustion technology is mature and the opportunities • Redox calcium oxide/carbonate system
for cost breakthrough are limited. • Membrane reaction processes
• Membrane water gas shift reaction
New technologies could reduce the cost of CO2 avoided by
o Low temperature H2 membrane separation
20-30% from the current BAT.
o Petroleum coke and gas fed schemes
• Membrane reforming with high temperature H2
Electrical Swing Adsorption offers no cost saving from BAT.
membrane separation
The combination of the Kvaerner Membrane Contactor with
Integration and Standardisation:
the Kansai/Mitsubishi advanced solvent has significantly
improved performance and cost, but the total cost of the • Advanced separation for IGCC gasification schemes
system is still too high for meaningful commercial application. • Economy of scale in very large scale autothermal
reforming
Physical adsorption systems will only be effective if they can • Standardised capture systems for repeat build
adsorb greater than 40% of their surface area with CO2. • Advanced syngas technologies
by optimization of the boilers for oxyfiring (boilers are more with conventional air separation would require consistent and
easily modified for oxyfiring than process heaters). However, very expensive development in the field of gas turbines to
none of the options studied would make a significant maintain high energy efficiency, given the cost of air
difference to the cost of CO2 capture, so CCP diverted its compression and flue gas recycle. At this time, vendors are
resources to other areas. not willing to engage in such development without a market.
2. Advanced Thermodynamic Cycles Oxyfiring significantly reduces NOx emissions from the
Oxyfiring produces flame temperatures well beyond current combustion process (NOx is usually generated by the high
turbine capabilities. The most obvious way to moderate temperature reaction between nitrogen and oxygen in
combustion temperature is to recycle exhaust gas, (CO2 in the conventional air combustion). The additional benefit of NOx
case of oxyfiring). However, this causes a large reduction in reduction has not been quantified or valued in this phase of the
net power output from the turbine system. Several alternative CCP, but should be taken into consideration for future work.
power cycles are proposed in the literature, but they would all
require tens of millions of dollars to be spent developing new Oxyfuel technologies will work well in steam generation
turbines, which would take many years and was out-with the scenarios, revamping or replacing existing heaters or boilers,
scope of CCP. in the CCP’s UK refinery scenario and for gas turbine power
generation scenarios, like CCP’s Norwegian and Alaskan
3. Novel Technologies for Air Separation scenarios. In the latter case, however, modifications to current
A very promising novel technology for air separation is ionic commercial machines are necessary to maintain high
transport membranes (ITM). These ceramic membranes, thermodynamic efficiency.
operate at high temperature (> 700°C) and allow 100%
selectivity to oxygen, which is transferred in anionic form It is unlikely that new boiler designs could significantly reduce
using oxygen partial pressure ratio between the two sides of the cost of CO2 capture.
the membrane as driving force.
Recommendations for Further Work
4. Equipment Integration Further significant cost reductions may be realized from the
The studies above showed that advances can be made air separation activity, however the novel membrane systems
separately for both air separation and oxyfiring, however a for oxygen production, currently under development may not
greater prize could probably be gained by integrating the two be suitable for the retrofit of existing boiler systems, due to the
steps. Two studies were commissioned by the CCP to assess incomplete extraction of oxygen from air.
the potential for integrating the ion transport air separation
membrane with the combustion process: The application of oxyfiring to new-build systems (including
power generation in CCGT) looks very promising and should
1. The Advanced Zero Emission Power (AZEP) would be further investigated.
integrate the membrane with gas turbines
2. The Advanced Boiler concept would integrate the Integrating novel membranes into boilers or gas turbines is
membrane with boilers still at an early stage of development, however, it offers
significant potential to reduce capture costs. Development risk
5. Chemical Looping is still high and commercialization is unlikely before 2010.
Chemical Looping is a new combustion technology based on
oxygen transfer from combustion air to the fuel by means of a Chemical Looping technology produces very high purity CO2
metal oxide acting as an oxygen carrier. Central to the and it offers significant cost-reduction opportunities with
technology is a two fluidized bed reactors system with reasonable scale-up risks. The next phase of CCP should
continuous circulation of solids, similar to Circulating explore high-pressure application of chemical looping to
Fluidized Boilers (CFB) used for coal combustion. The CCGTs.
reactions are schematically:
Some benefits could be derived from the combination of
Fuel reactor: MeO + CH4 ⇒ Me + 2H2O + CO2 technologies developed by the Oxyfuel and PCDC programs.
Air reactor: Me + 0.5O2 ⇒ MeO
Storage, Monitoring and Verification (SMV)
Summary of Results Relative to capture, the cost of storage is well understood
For heaters and boilers, oxyfiring with flue gas recycle is a because there are a large number of CO2 Enhanced Oil
proven technology that now requires only a full-scale Recovery (EOR) and natural gas storage projects that provide
demonstration to become commercial. excellent analogs for the geological storage of CO2. So the
SMV team focused on the relatively unexplored areas of seal
Several new technologies are under development, which could integrity and assurance. The team had two key objectives
reduce the cost of CO2 avoided for new-build application by
30 - 50% from the current BAT. • Determine the key principles and practices to maximize
the volume of CO2, which can be safely sequestered in
Oxyfiring of Combined Cycle Gas Turbine (CCGT) systems geologic formations.
4 SPE 86602
Conclusions
Capture and geological storage could provide a significant
option for GHG mitigation.
The greatest cost associated with CCS from dilute sources will
be the cost of capture (separation from the diluant).
Screening favored
?30 Capture & 50 storage
technologies
Techs Screened
50 50 Techs Pass Stage Gate ?
0 Review & Evaluation Analysis Broad Tech Development Focused Tech Development
Apr 2000 Aug 2000 Sep 2001 Dec 2002 Dec 2003
¾Technical
¾Advisory
¾Program
¾Board
¾Manager
¾Storage, ¾Common
¾Pre ¾Post ¾Policy & ¾Commu-
¾Oxyfuel ¾Monitoring & ¾Economic
¾Combustion ¾Combustion ¾Incentives ¾nications
¾Verification ¾Modelling
¾Media -
¾Technology Providers ¾NGO/
¾TV, Print,
¾Universities, National Laboratories, Engineering Consultants, Specialists ¾Outreach
¾Internet
SPE 86602 9
Sky Sky
N2
O2
Amine CO2
Absorption
• Enhanced Coal
Precombustion Reformer H2
N2 O2 CO2 Bed Methane
Decarbonisation + CO2 Sep
Air
Power & Heat Compression
& Dehydration • Old Oil/Gas
CO2 Fields
Oxyfuel Power & Heat
• Saline
O2 Formations
N2
Air Air Separation Unit
Fossil Fuel
Natural
Refinery UK, Europe Gas & Retrofit 4.0 8%
Liquids
Petroleum Coke
Canada Coke Newbuild 7.4 10.5%
Gasification
10 SPE 86602
O2
Air Air N2
Separation