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Gasification Combined Cycle:  Carbon Dioxide Recovery, Transport, and Disposal - 1994

Doctor, R. D.
Molburg, J. C.
Thimmapuram, P. R.
Berry, G. F.
Livengood, C. D.

Argonne National Laboratory

Part 1, Pages 1 - 66, 3.60 MB
Part 2, Pages 67 - 200, 5.25 MB

Table of Contents

Part 1

1.

Acknowledgements

xi

2.

Notation

xii

3.

Abstract

1

4.

Summary

1

S.1

Overview of Energy Cycle

3

S.2

Mining, Preparation, and Transportation of Raw Materials

5

S.3

Handling of Coal and Limestone

6

S.4

Base Case for Integrated Gasification Combined Cycle

6

S.5

Integrated Gasification Combined Cycle with CO2 Recovery

7

S.6

Pipeline Transport of CO2

9

S.7

Sequestering of CO2

10

S.8

Comparison of Power and CO2 Emissions for IGCC/Shift/CO2 Recovery System

11

S.9

Economics of CO2 Recovery, Transport, and Sequestering

13

S.9.1

Direct Costs for IGCC/Shift/CO2 Recovery

13

S.9.2

Direct Costs for Pipeline

14

S.9.3

Costs of Replacement Electricity

14

S.9.4

Summation of Capital, Operating, and Replacement Electricity Costs

15

S.10

References for Summary

16

1.0

Introduction

17

1.1

Background

17

1.2

Goals, Objectives, and Approach

17

2.

Mining

20

2.1

Extraction

20

2.1.1

Deep Mining

21

2.1.2

Coal-Cleaning Circuit

22

2.2

Rail Transport

23

2.3

Impact of Plant Location on CO2 Budget

23

2.4

Economics

24

2.5

Limestone Mining

24

2.6

Limestone Rail Transport

25

3.

Kellogg-Rust-Westinghouse IGCC:  Coal and Limestone Preparation

26

4.

Kellogg-Rust-Westinghouse IGCC:  Gasifier

26

4.1

Overview

27

4.1.1

Description of the Gasifier

27

4.1.2

Shift Reaction

28

4.1.3

Recovery Process

29

4.2

Shift Reaction

31

4.3

Heat Recovery and Process Integration

38

5.

Integrated Gasification Combined Cycle with Amine CO2 Recovery

44

5.1

Feed Gas Preparation and Process Integration

44

5.2

Carbon Dioxide Recovery by Amines

45

5.3

Power System Performance Effects of the MEA Process

53

5.4

Major Equipment Specification and Preliminary Cost Estimation

53

5.4.1

Heat Exchanger before First-Stage Shift Reactor

53

5.4.2

Heat Exchanger between First and Second Shift Reactors

54

5.4.3

Heat Exchanger after Second-Stage Shift Reactor

63

5.4.4

First-Stage Shift Reactor

64

5.4.5

Second-Stage Shift Reactor

64

5.4.6

Cost of Catalyst

64

5.4.7

Absorption Tower

64

5.4.8

Stripping Column

64

5.4.9

Lean Solvent Cooler

64

5.4.10

Interstage Cooler for Absorber

64

5.4.11

Lean-Rich MEA Heat Exchanger

65

5.4.12

Stripper Overhead Condenser

65

5.4.13

Stripper Reboiler

65

5.4.14

Solvent Circulation Pump

65

5.4.15

Carbon Dioxide Product Gas Compressors

66

Part 2

6.

Integrated Gasification Combined Cycle with Glycol Solvent CO2 Recovery

67

6.1

Feed Gas Preparation and Process Integration

67

6.2

Carbon Dioxide Recovery by a Glycol Solvent

67

6.3

Power System Performance Effects of the Glycol Solvent Process

72

6.4

Major Equipment Specification and Preliminary Cost Estimation

72

6.4.1

High-Pressure Glycol Solvent Case

72

6.4.2

Low-Pressure Glycol Solvent Case

97

7.

Integrated Gasification Combined Cycle with Chilled Methanol CO2 Recovery

109

7.1

Feed Gas Preparation and Process Integration

109

7.2

Carbon Dioxide Recovery by Chilled Methanol

109

7.3

Power System Performance Effects of the Chilled Methanol Process

120

7.4

Major Equipment Specification and Preliminary Cost Estimation

121

7.4.1

Heat Exchanger before First-Stage Shift Reactor

121

7.4.2

Heat Exchanger between First and Second Shift Reactor

121

7.4.3

Heat Exchanger after Second-Stage Shift Reactor

121

7.4.4

Heat Exchanger for Raw Gas Cooling

130

7.4.5

First-Stage Shift Reactor

130

7.4.6

Second-Stage Shift Reactor

130

7.4.7

Cost of Catalyst

130

7.4.8

Absorption Tower

130

7.4.9

Stripping Column

131

7.4.10

Flash Tank 1

131

7.4.11

Recycle Gas Compression

131

7.4.12

Flash Tank 2

131

7.4.13

Flash Tank 3

131

7.4.14

Flash Gas Compressor 1

132

7.4.15

Flash Gas Compressor 2

132

7.4.16

Solvent Circulation Pump

132

7.4.17

Lean-Rich Methanol Heat Exchanger

132

7.4.18

Carbon Dioxide product Gas Compressors

132

7.4.19

Solvent Refrigeration

132

8.

Integrated Gasification Combined Cycle with Hot Potassium Carbonate CO2 Recovery

133

8.1

Feed Gas Preparation and Process Integration

133

8.2

Carbon Dioxide Recovery by Hot Potassium Carbonate

134

8.3

Power System Performance Effects of the Hot Potassium Carbonate Process

142

8.4

Major Equipment Specification and Preliminary Cost Estimation

142

8.4.1

Heat Exchanger before First-Stage Shift Reactor

142

8.4.2

Heat Exchanger Between First and Second Stage Shift Reactor

142

8.4.3

Heat Exchanger After Second-Stage Shift Reactor

147

8.4.4

First-Stage Shift Reactor

148

8.4.5

Second-Stage Shift Reactor

148

8.4.6

Cost of Catalyst

148

8.4.7

Absorption Tower

148

8.4.8

Stripping Column

148

8.4.9

Lean Solvent Cooler

149

8.4.10

Stripper Overhead Condenser

149

8.4.11

Solvent Circulation Pump

149

8.4.12

Carbon Dioxide Product Gas Compressors

149

9.

Integrated Gasification Combined Cycle with Calcium Oxide CO2 Recovery

150

9.1

Background

150

9.2

Sorbents

150

9.3

Optimum Conditions for Reaction

151

9.4

Carbon Dioxide Capture:  Carbonation

151

9.5

Carbon Dioxide Release:  Calcination

151

9.6

Macroscale Physical Propertied of the Sorbent, Support Geometry, and Bed Depth

152

9.7

Louisiana State University Carbonation as a Shift Reactor

152

9.8

Process Performance with Trace Gases

152

10.

Integrated Gasification Combined Cycle with Low-Temperature Polymer Membrane CO2 Recovery

153

10.1

Gas Pretreatment and Operating Conditions

153

10.2

Polymer Membrane Selectivity

153

10.3

Membrane Separation:  Conclusions

154

11.

Transport of CO2 by Pipeline

155

11.1

Commercial Considerations of CO2 Separation Systems for Pipeline Gas

155

11.2

Supercritical Compression for CO2 Pipeline

156

11.3

Substation Recompression

158

11.4

Total Power Consumption for CO2 Pipeline

159

11.5

Costs for CO2 Pipeline:  Compression and Dehydration

159

11.6

Commercial Pipelines

163

12.

Sequestering of CO2

165

12.1

Overview of Geologic Processes:  The Dominance of Ocean Sequestering

165

12.2

Terrestrial Biological Sequestering

167

12.3

Ocean Sequestering

168

12.4

Geologic Sequestering:  Aquifers

168

12.5

Geologic Sequestering:  Depleted Oil and Gas Reservoirs

169

12.5.1

Natural Gas Outflow Calculations

169

12.5.2

Inflow Calculations

173

12.6

Conclusions

176

13.

Conclusions

177

13.1

Summary of Energy Consumption and CO2 Emissions

177

13.1.1

Base-Case IGCC

177

13.1.2

IGCC/Shift/Amine CO2 Recovery Case

177

13.1.3

IGCC/Shift/Glycol CO2 Recovery Case

177

13.1.4

IGCC/Shift/Methanol CO2 Recovery Case

178

13.1.5

IGCC/Shift/Carbonate CO2 Recovery Case

182

13.2

Summary of Economics

182

13.2.1

Direct Costs for IGCC/Shift/CO2 Recovery

182

13.2.2

Direct Costs for Pipeline

186

13.2.3

Costs for Replacement Electricity

189

13.2.4

Summation of Capital, Operating, and Replacement-Electricity Costs

195

14.

References

196