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Application of optimal design methodologies in retrofitting natural gas combined cycle power plants with CO2 capture

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  • Pan, Ming
  • Aziz, Farah
  • Li, Baohong
  • Perry, Simon
  • Zhang, Nan
  • Bulatov, Igor
  • Smith, Robin

Abstract

Around 21% of the world’s power production is based on natural gas. Energy production is considered to be the significant sources of carbon dioxide (CO2) emissions. This has a significant effect on the global warming. Improving power plant efficiency and adding a CO2 capture unit into power plants, have been suggested to be a promising countermeasure against global warming. This paper presents a new insight to the application of energy efficient technologies in retrofitting natural gas combined cycle (NGCC) power plants with CO2 capture. High fidelity models of a 420MW NGCC power plant and a CO2 capture plant with CO2 compression train have been built and integrated for 90% capture level. These models have been then validated by comparisons with practical operating data and literature results. The novelty of the paper is to propose optimal retrofitting strategies to minimize the efficiency penalty caused by integrating carbon capture units into the power plant, including (1) implementing heat transfer intensification techniques to increase energy saving in the heat recovery steam generator (HRSG) of the power plant; (2) extracting suitable steam from the HRSG to supply the heat required by the capture process, thus on external heat is purchased; (3) employing exhaust gas recirculation (EGR) to increase the overall energy efficiency of the integrated process, which can benefit both power plant (e.g. increasing power plant efficiency) and capture process (e.g. reducing heat demands). Compared with the base case without using any integrating and retrofitting strategies, the optimal solution based on the proposed approaches can provide sufficient heat to CO2 capture process, and keep the same power generation. The optimal solution shows that, the flue gas flow-rate is reduced 33% in the inlet of CO2 capture process, heat demand in CO2 capture decreases 4.3%, heat output from the power plant increases from 0MW to 133MW, and more than 22% of profit is obtained in the integrated system. This demonstrates the validity and efficiency of the proposed approaches in retrofitting existing NGCC power plants with CO2 capture.

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  • Pan, Ming & Aziz, Farah & Li, Baohong & Perry, Simon & Zhang, Nan & Bulatov, Igor & Smith, Robin, 2016. "Application of optimal design methodologies in retrofitting natural gas combined cycle power plants with CO2 capture," Applied Energy, Elsevier, vol. 161(C), pages 695-706.
    • Handle: RePEc:eee:appene:v:161:y:2016:i:c:p:695-706
    DOI: 10.1016/j.apenergy.2015.03.035
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    9. Shen, Wenkai & Xing, Chang & Liu, Haiqing & Liu, Li & Hu, Qiming & Wu, Guohua & Yang, Yujia & Wu, Shaohua & Qiu, Penghua, 2022. "Exhaust gas recirculation effects on flame heat release rate distribution and dynamic characteristics in a micro gas turbine," Energy, Elsevier, vol. 249(C).
    10. Calise, Francesco & de Notaristefani di Vastogirardi, Giulio & Dentice d'Accadia, Massimo & Vicidomini, Maria, 2018. "Simulation of polygeneration systems," Energy, Elsevier, vol. 163(C), pages 290-337.
    11. Jiang, L. & Gonzalez-Diaz, A. & Ling-Chin, J. & Roskilly, A.P. & Smallbone, A.J., 2019. "Post-combustion CO2 capture from a natural gas combined cycle power plant using activated carbon adsorption," Applied Energy, Elsevier, vol. 245(C), pages 1-15.
    12. Oh, Se-Young & Yun, Seokwon & Kim, Jin-Kuk, 2018. "Process integration and design for maximizing energy efficiency of a coal-fired power plant integrated with amine-based CO2 capture process," Applied Energy, Elsevier, vol. 216(C), pages 311-322.
    13. Jing Bian & Liqiang Duan & Yongping Yang, 2023. "Simulation and Economic Investigation of CO 2 Separation from Gas Turbine Exhaust Gas by Molten Carbonate Fuel Cell with Exhaust Gas Recirculation and Selective Exhaust Gas Recirculation," Energies, MDPI, vol. 16(8), pages 1-21, April.
    14. Adams, T. & Mac Dowell, N., 2016. "Off-design point modelling of a 420MW CCGT power plant integrated with an amine-based post-combustion CO2 capture and compression process," Applied Energy, Elsevier, vol. 178(C), pages 681-702.
    15. Yingjian, Li & Abakr, Yousif A. & Qi, Qiu & Xinkui, You & Jiping, Zhou, 2016. "Energy efficiency assessment of fixed asset investment projects – A case study of a Shenzhen combined-cycle power plant," Renewable and Sustainable Energy Reviews, Elsevier, vol. 59(C), pages 1195-1208.
    16. Oh, Se-Young & Kim, Jin-Kuk, 2018. "Operational optimization for part-load performance of amine-based post-combustion CO2 capture processes," Energy, Elsevier, vol. 146(C), pages 57-66.
    17. Kazemi, Abolghasem & Moreno, Jovita & Iribarren, Diego, 2022. "Techno-economic comparison of optimized natural gas combined cycle power plants with CO2 capture," Energy, Elsevier, vol. 255(C).
    18. Xiang, Yanlei & Cai, Lei & Guan, Yanwen & Liu, Wenbin & Han, Yixiao & Liang, Ying, 2018. "Study on the configuration of bottom cycle in natural gas combined cycle power plants integrated with oxy-fuel combustion," Applied Energy, Elsevier, vol. 212(C), pages 465-477.
    19. Pan, Ming & Sikorski, Janusz & Akroyd, Jethro & Mosbach, Sebastian & Lau, Raymond & Kraft, Markus, 2016. "Design technologies for eco-industrial parks: From unit operations to processes, plants and industrial networks," Applied Energy, Elsevier, vol. 175(C), pages 305-323.
    20. Otitoju, Olajide & Oko, Eni & Wang, Meihong, 2021. "Technical and economic performance assessment of post-combustion carbon capture using piperazine for large scale natural gas combined cycle power plants through process simulation," Applied Energy, Elsevier, vol. 292(C).
    21. Farajollahi, Hossein & Hossainpour, Siamak, 2017. "Application of organic Rankine cycle in integration of thermal power plant with post-combustion CO2 capture and compression," Energy, Elsevier, vol. 118(C), pages 927-936.
    22. Yuxing Liu & Linjun Zeng & Jie Zeng & Zhenyi Yang & Na Li & Yuxin Li, 2023. "Scheduling Optimization of IEHS with Uncertainty of Wind Power and Operation Mode of CCP," Energies, MDPI, vol. 16(5), pages 1-17, February.
    23. Wu, Xiao & Wang, Meihong & Shen, Jiong & Li, Yiguo & Lawal, Adekola & Lee, Kwang Y., 2019. "Reinforced coordinated control of coal-fired power plant retrofitted with solvent based CO2 capture using model predictive controls," Applied Energy, Elsevier, vol. 238(C), pages 495-515.
    24. Li, Kangkang & Leigh, Wardhaugh & Feron, Paul & Yu, Hai & Tade, Moses, 2016. "Systematic study of aqueous monoethanolamine (MEA)-based CO2 capture process: Techno-economic assessment of the MEA process and its improvements," Applied Energy, Elsevier, vol. 165(C), pages 648-659.

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