A Perspective on Transition Engineering Options from Capture-Readiness to Full Size Capture on Natural Gas Combined Cycle Plants

11th September 2014, UKCCSRC bi-annual meeting, Cardiff University

A perspective on transition engineering options from capture-readiness to full size capture on Natural Gas Combined Cycle Plants

Dr Mathieu Lucquiaud, Laura Herraiz, Abigail Gonzalez, Jon Gibbins University of Edinburgh [email protected]

Overview

 Carbon Capture and Storage on gas power generation: context and drivers

 What future gas power plants may look like?  Retrofitted capture-ready station?  Retrofitted with Exhaust Gas Recycling?  Low water consumption?  Selective Exhaust Gas Recycling?  Supplementary firing for EOR projects?

CCS from gas power plants has become increasingly important

UK Percentage shares of fuel input for electricity generation, 1970 to 2013

Us shale gas displacing US coal to Europe

Digest of UK Energy Statistics (DUKES) 2014 3 Snapshot of recent development of CCS in the UK 2013/2014: 2 FEED study contracts awarded:

Gas CCS is commercially available

Peterhead

Peterhead White Rose World’s first commercial World’s largest Oxyfuel scale gas CCS project power plant Reuse of existing North Yorkshire / Humber CCS White Rose Sea infrastructure Trunkline FEED contract signed 24 FEED contract signed 20 February 2014 December 2013

Gas-fired capacity permitted in England and Wales since 2007 Location Type of project Size MW Date of decision Thorpe Marsh Ltd, Doncaster CCGT 1500 31.10.11 Gateway Energy Centre Ltd, Manorway, Essex CCGT 900 04.08.11 RWE Npower, Willington C, Derbyshire CCGT/OCGT 2400 04.03.11 Abernedd Power Co Ltd, Baglan Bay CCGT/OCGT 870 23.02.11 Scottish Power Damhead Creek CCGT 1000 25.01.11 Spalding Energy Expansion Ltd CCGT 900 11.11.10 Wainstones Energy Ltd Carrington CCGT 1520 01.04.10 Norsea Pipelines Ltd Seal Sands Teesside CHP CCGT 800 22.04.09 RWE Npower Pembroke CCGT 2000 05.02.09 Centrica Leasing (KL) Kings Lynn B Norfolk CCGT 1020 05.02.09 Powerfuel Power Hatfield Park Doncaster CCGT 900 05.02.09 Thor Cogeneration Seal Sands,Teeside CHP CCGT 1020 28.08.08 Bridestones Developments Ltd Carrington CCGT 860 30.07.08 Barking Power Station Dagenham,Essex CCGT 1000 19.12.07 EDF Energy West Burton Power Station Nottinghamshire CCGT 1270 30.10.07 E.on UK Drakelow South Derbyshire CCGT 1220 16.10.07 Severn Power Ltd Uskmouth Newport CCGT 800 17.08.07 Total 20 GW https://www.og.decc.gov.uk/EIP/pages/recent.htm Gas-fired capacity permitted in Scotland since 2007 Applications under consideration Type of project Size MW Date of decision Cockenzie Power Station CCGT/OCGT 1000 05.10.2011 Total 1 GW http://www.scotland.gov.uk/Topics/Business-Industry/Energy/Infrastructure/Energy-Consents/Applications-Database All new coal and gas power stations in the EU/UK have to be carbon capture ready

http://www.decc.gov.uk/en/content/cms/what_we_do/uk_supply/energy_mix/ccs/ccs.aspx Overview

 Carbon Capture and Storage on gas power generation: context and drivers

Exhaust Gas Recirculation – The concept • Initially developed by GT manufacturers as a NOx reduction measure in the 1990s • Advantages for Carbon capture are: reduction in gas flow rates, higher CO2 and lower O2 concentration in flue gas Exhaust Gas Recirculation – The concept

• EGR ratios up to 35% are feasible with current technologies -> O2 concentration in combustion air around 16-18 % vol. -> CO2 concentration up to 6 %vol. (based on GE technology based DLN gas turbine combustor)

• EGR ratio up to 40% are possible with minor modifications to the combustion design

• The fundamental limit to EGR is stoichiometric combustion, achieved with an EGR ratio around 60% Overview

 Carbon Capture and Storage on gas power generation: context and drivers

Heat and water management of flue gas in gas turbine with capture

• Pressure on water resources from the power sector is unlikely to alleviate pressure on water usage from CCS power plants

• Water withdrawal and water consumption is expected to increased significantly for CCS power plants using wet- cooling

• It is feasible to build CCS power plants with dry cooling technologies for sites where access to water is limited Rotary gas/gas heat exchangers: A novel integration option for heat and water management Flue gas pathway configurations with EGR

Gas/Gas Heater and Air/Gas Heater in series

Gas/Gas/Air heater configuration Tri-sector gas/has heaters with an additional sector for air cooling

• Booster fan location influences the direction of leakage. • Leakage rates can be actively mitigated down to 0.5-1% v/v • The direction of rotation is important for solvent emission management Cooling water, process water and cooling air mass flow based on a 285MW GT (~x2 for 800MW CCGT plant) 1000

900

800

700

600

500

400

Mass Mass flow rate (kg/s) 300

200

100

0 DCC DCC GGH and GGH and GGH and GGH and GGAH GGAH (EGR 40%) DCC DCC AGH AGH (EGR 40%) (EGR 40%) (EGR 40%) DCC : direct contact cooler Cooling water mass flow GGH and DCC : gas/gas heater and direct contact cooler GGH and AGH : gas/gas heater and air/gas heater Process water mass flow GGAH : gas/gas/air heater tri-sector heater Cooling air mass flow Minimal additional fan power for Gas/Gas/Air heater based on a 285MW GT (~x2 for 800MW CCGT plant) 12.0

10.0

8.0

6.0

4.0 Fan Power (MW)

2.0

0.0 DCC DCC GGH and GGH and GGH and GGH and GGAH GGAH (air fired) (EGR 40 %) DCC DCC AGH AGH (air fired) (EGR 40%) (air fired) (EGR 40%) (air fired) (EGR 40%) DCC : direct contact cooler Water pumps power consumption GGH and DCC : gas/gas heater and direct contact cooler Air fan power consumption GGH and AGH : gas/gas heater and air/gas heater GGAH : gas/gas/air heater tri-sector heater Booster fan power consumption Overview

 Carbon Capture and Storage on gas power generation: context and drivers

Selective Exhaust Gas Recirculation – The concept Getting closer to thermodynamic limits for separation and compression with Selective EGR

Merkel et al (2012) Selective EGR with Membranes for CO2 capture from CCGT, Ind. Eng. Chem. Res. 2013, 52, 1150−1159 Comparison of O2 and CO2 levels in Selective and Conventional Exhaust Gas Recycling Gas Turbine systems 25%

Turbine Inlet Temperature 1371 ºC

20%

15% concentration (%vol)concentration 10%2 O2 levels at Combustor Inlet with EGR

and CO CO2 levels at turbine outlet 2

O with EGR O2 levels at combustor inlet 5% with Selective EGR CO2 levels at turbine outlet with Selective EGR O2 levels combustion limit with EGR (Elkady et al, 2007) 0% 0 0.2 0.4 0.6 0.8 1 Recycling ratio Selective Exhaust Gas Recirculation for Carbon Capture with Gas Turbines: Integration, Intensification, Scale-up and Optimisation (SELECT) EPSRC £1.1M (£1.4M at 100%fEC) – Cardiff, Edinburgh, Leeds PI: Dr Richard Marsh

WP 1. System Integration and Process Intensification of Selective EGR Gas Turbines (Edinburgh)

WP 2: System scale-up: pilot plant studies (Cardiff)

WP 3: System optimisation and whole systems performance assessment (Leeds)

WP 4: Selective EGR CCGT design guidelines, impact and dissemination (Cardiff)

Industry expert panel WP 1. System Integration and Process Intensification of Selective EGR Gas Turbines (Edinburgh) WP 1.1: Selective EGR system concept and modelling (Edinburgh): WP 1.2 Novel absorber configurations for selective EGR gas turbine capture (Edinburgh) WP 1.3: Integration of gas turbine operation with an amine capture pilot: ramping and part-load behaviour (Leeds)

WP 2: System scale-up: pilot plant studies (Cardiff) WP 2.1 Flame stability and burner operation with Selective EGR (Cardiff) WP 2.2 Gas Turbine operation at varying Selective EGR ratio (Leeds) WP 2.3 Amine pilot plant test programme with Selective EGR (Leeds) WP 2.4 Tomography at amine pilot (Edinburgh)

WP 3: System optimisation and whole systems performance assessment (Leeds) WP 3.1 Dynamic simulation (Leeds) WP3.2 Multiphase CFD for absorber (Edinburgh)

WP 4: Selective EGR CCGT design guidelines, impact and dissemination (Cardiff) Overview

 Carbon Capture and Storage on gas power generation: context and drivers

Process flow diagram a Natural Gas power plant with a Sequential Supplementary Firing Combined Cycle

HPST IPST Gonzalez et al HPST LPST (GHGT12)

14 23

26 Steam to reboiler

GAS 24 BINE 22

25 21 17 18 19 39 bar 8. 4°C Flue gas REHEAT 1 3.6 kg/s HPSH0 from GT 10 11 12 13 REHEAT2 1 2 3 HPSH1 4 5 IPE2 6 7 OTS 8 9 HPE3 HPE2 LTE

HPSH3

Supplementary Supplementary Supplementary Supplementary Supplementary firing 1 firing 2 firing 3 firing 4 firing 5 20

15 16 HRSG heat transfer diagram of a Sequential Supplementary Firing Combined Cycle 900 Gonzalez et al (GHGT12) 800

700

600

500

400

Temperature ( ° C) Temperature 300

200 Flue gas HP steam 100 IP steam

0 0 250000 500000 750000 1000000 1250000 1500000 Heat duty (KW) Supplementary Sequential Firing - principles

(comparison with a standard NGCC w capture and EOR) • Additional natural gas combustion to boost CO2 production for EOR • Lower marginal efficiency of natural gas usage (48% vs 60% in state-of-the-art CCGT. -> No mechanical work in a GT for the additional gas and higher irreversibilities in HRSG • Number of capital intensive gas turbines and HRSGs is reduced from 2 to 1 • Loss of efficiency mitigated by moving to supercritical steam conditions • Reduction of absorber capital costs (on a tonne of CO2 basis) Breakeven additional capital cost for NG Sequential Supplementary Firing Combined Cycle plant for a range of fuel price and CO2 prices

The counterfactual is the most profitable of either a NGCC plant w/o capture or a NGCC plant with capture and EOR

North American CO2 prices for EOR

Gonzalez et al (GHGT12) Where could this be deployed?

Mexico has legally binding CO2 targets (the only country with the UK) and a CCS roadmap to develop EOR in the Gulf of Mexico

Localization of industrial CO2 sources (LHS) and the main oil reservoirs in the Gulf of Mexico region (RHS) (Gonzalez et al, GHGT12)

Conclusions Gas CCS is commercially available (Peterhead) Capture-ready gas power stations should facilitate transition to carbon capture and storage Permutations around the gas turbine and the combined cycle can help greatly to facilitate deployment of gas CCS for the next generation of plants • Exhaust Gas Recycling • Selective Exhaust Gas Recycling A possible transition pathway for the UK is Capture-ready -> post-combustion capture -> exhaust (or selective) gas recycling

Other permutations in different markets, e.g. Mexico, USA