Source: https://patents.justia.com/patent/20130104563
Timestamp: 2019-11-21 08:15:34
Document Index: 409702964

Matched Legal Cases: ['application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'art-8']

US Patent Application for Low Emission Triple-Cycle Power Generation Systems and Methods Patent Application (Application #20130104563 issued May 2, 2013) - Justia Patents Search
Justia Patents Having Power Output ControlUS Patent Application for Low Emission Triple-Cycle Power Generation Systems and Methods Patent Application (Application #20130104563)
Low Emission Triple-Cycle Power Generation Systems and Methods
This application claims the benefit of U.S. provisional patent application No. 61/361,173, filed Jul. 2, 2010 entitled Low Emission Triple-Cycle Power Generation Systems and Methods, the entirety of which is incorporated by reference herein.
This application contains subject matter related to U.S. Patent Application No. 61/361,169, filed Jul. 2, 2010 entitled “Systems and Methods for Controlling Combustion of a Fuel”; U.S. Patent Application No. 61/361,170, filed Jul. 2, 2010 entitled “Low Emission Triple-Cycle Power Generation Systems and Methods”; U.S. Patent Application No. 61/361,176, filed Jul. 2, 2010, entitled “Stoichiometric Combustion With Exhaust Gas Recirculation and Direct Contact Cooler”; U.S. Patent Application No. 61/361,178, filed Jul. 2, 2010, entitled “Stoichiometric Combustion of Enriched Air With Exhaust Gas Recirculation” and U.S. Patent Application No. 61/361,180 filed Jul. 2, 2010, entitled “Low Emission Power Generation Systems and Methods”.
Embodiments of the disclosure relate to low emission power generation in combined-cycle power systems. More particularly, embodiments of the disclosure relate to methods and apparatuses for stoichiometrically combusting a fuel for enhanced CO2 manufacture and capture, and expansion or compression of nitrogen-rich gas.
Some approaches to lower CO2 emissions include fuel de-carbonization or post-combustion capture using solvents, such as amines. However, both of these solutions are expensive and reduce power generation efficiency, resulting in lower power production, increased fuel demand and increased cost of electricity to meet domestic power demand. In particular, the presence of oxygen, SOx, and NOx components makes the use of amine solvent absorption very problematic. Another approach is an oxyfuel gas turbine in a combined cycle (e.g., where exhaust heat from the gas turbine Brayton cycle is captured to make steam and produce additional power in a Rankin cycle). However, there are no commercially available gas turbines that can operate in such a cycle and the power required to produce high purity oxygen significantly reduces the overall efficiency of the process. Several studies have compared these processes and show some of the advantages of each approach. See, e.g. BOLLAND, OLAV, and UNDRUM, HENRIETTE, Removal of CO2 from Gas Turbine Power Plants: Evaluation of pre- and post-combustion methods, SINTEF Group, found at http://www.energy.sintef.no/publ/xergi/98/3/3 art-8-engelsk.htm (1998).
Other approaches to lower CO2 emissions include stoichiometric exhaust gas recirculation, such as in natural gas combined cycles (NGCC). In a conventional NGCC system, only about 40% of the air intake volume is required to provide adequate stoichiometric combustion of the fuel, while the remaining 60% of the air volume serves to moderate the temperature and cool the flue gas so as to be suitable for introduction into the succeeding expander, but also disadvantageously generate an excess oxygen byproduct which is difficult to remove. The typical NGCC produces low pressure flue gas which requires a fraction of the power produced to extract the CO2 for sequestration or EOR, thereby reducing the thermal efficiency of the NGCC. Further, the equipment for the CO2 extraction is large and expensive, and several stages of compression are required to take the ambient pressure gas to the pressure required for EOR or sequestration. Such limitations are typical of post-combustion carbon capture from low pressure flue gas associated with the combustion of other fossil fuels, such as coal.
Accordingly, there is still a substantial need for a low emission, high efficiency power generation and CO2 capture or manufacture process.
The present disclosure is directed to triple-cycle power generation systems and methods of operating the system. In one exemplary system, an integrated system comprises a gas turbine system, an exhaust gas recirculation system, and a gas expander. The gas turbine system has a first combustion chamber configured to stoichiometrically combust a first compressed oxidant and a first fuel in the presence of a compressed recycle stream. The combustion chamber directs a first discharge stream to an expander to generate a gaseous exhaust stream and at least partially drive a main compressor. The exhaust gas recirculation system receives the gaseous exhaust stream from the expander of the gas turbine system and produces power from the heat energy contained therein, such as through a heat recovery steam generation unit. The exhaust gas recirculation system further routes the exhaust gas stream to the main compressor where it is compressed to generate the compressed recycle stream. The compressed recycle stream is directed to the combustion chamber to act as a diluent configured to moderate the temperature of the first discharge stream. The integrated system further includes a CO2 separator fluidly coupled to the compressed recycle stream via a purge stream. The CO2 separator generates a CO2-rich stream and a residual stream, comprising nitrogen-rich gas, from the purge stream. As indicated above, the integrated system also includes a gas expander. The gas expander is fluidly coupled to the CO2 separator via the residual stream as is adapted to generate power by expanding the residual stream.
In an exemplary method of operating a triple-cycle power generation system, a method of generating power may comprise stoichiometrically combusting a first compressed oxidant and a first fuel in a first combustion chamber and in the presence of a compressed recycle stream. The combustion may thereby generate a first discharge stream. The compressed recycle stream may act as a diluent configured to moderate the temperature of the first discharge stream. The method further includes expanding the first discharge stream in an expander to at least partially drive a first compressor and generate a gaseous exhaust stream. The expansion of the first discharge stream may generate additional power for other uses. The method further includes directing the gaseous exhaust stream into the first compressor, wherein the first compressor compresses the gaseous exhaust stream and thereby generates the compressed recycle stream. Still further, the method includes extracting a portion of the compressed recycle stream to a CO2 separator via a purge stream, the CO2 separator being fluidly coupled to a gas expander via a residual stream derived from the CO2 separator and consisting primarily of nitrogen-rich gas. The exemplary method further includes expanding the residual stream in a gas expander to generate mechanical power and an exhaust gas.
FIG. 1 depicts an integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 2 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 3 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 4 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 5 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 6 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 7 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
FIG. 8 depicts another integrated system for low emission power generation and enhanced CO2 recovery, according to one or more embodiments of the present disclosure.
As used herein, the term “natural gas” refers to a multi-component gas obtained from a crude oil well (associated gas) or from a subterranean gas-bearing formation (non-associated gas). The composition and pressure of natural gas can vary significantly. A typical natural gas stream contains methane (CH4) as a major component, i.e. greater than 50 mol % of the natural gas stream is methane. The natural gas stream can also contain ethane (C2H6), higher molecular weight hydrocarbons (e.g., C3-C20 hydrocarbons), one or more acid gases (e.g., hydrogen sulfide, carbon dioxide), or any combination thereof. The natural gas can also contain minor amounts of contaminants such as water, nitrogen, iron sulfide, wax, crude oil, or any combination thereof.
As used herein, the term “stoichiometric combustion” refers to a combustion reaction having a volume of reactants comprising a fuel and an oxidizer and a volume of products formed by combusting the reactants where the entire volume of the reactants is used to form the products. As used herein, the term “substantially stoichiometric combustion” refers to a combustion reaction having a molar ratio of combustion fuel to oxygen ranging from about plus or minus 10% of the oxygen required for a stoichiometric ratio or more preferably from about plus or minus 5% of the oxygen required for the stoichiometric ratio. For example, the stoichiometric ratio of fuel to oxygen for methane is 1:2 (CH4+2O2>CO2+2H2O). Propane will have a stoichiometric ratio of fuel to oxygen of 1:5. Another way of measuring substantially stoichiometric combustion is as a ratio of oxygen supplied to oxygen required for stoichiometric combustion, such as from about 0.9:1 to about 1.1:1, or more preferably from about 0.95:1 to about 1.05:1
Combustion at near stoichiometric conditions (or “slightly rich” combustion) can prove advantageous in order to eliminate the cost of excess oxygen removal. By cooling the flue gas and condensing the water out of the stream, a relatively high content CO2 stream can be produced. While a portion of the recycled exhaust gas can be utilized for temperature moderation in the closed Brayton cycle, a remaining purge stream can be used for EOR applications and electric power can be produced with little or no SOX, NOX, or CO2 being emitted to the atmosphere. For example, according to embodiments disclosed herein, the purge stream can be treated in a CO2 separator adapted to discharge a nitrogen-rich gas which can be subsequently expanded in a gas expander to generate additional mechanical power. The result of the systems disclosed herein is the production of power in three separate cycles and the manufacturing or capture of additional CO2 at a more economically efficient level. In some implementations, the nitrogen-rich discharge stream may be heated through various means to increase the power obtainable through the expander on the nitrogen stream. Additionally, in some implementations, the nitrogen vent following the expander can be cooled and used to provide refrigeration, which can be used to improve the efficiency of the compressor(s) in the Brayton cycle and/or in recycling the exhaust gas. The cold nitrogen stream could also be used in other applications that improve the process efficiency.
Alternatively, the discharged nitrogen-rich gas can be sent to EOR facilities for additional compression and/or injection into wells for oil recovery and/or pressure maintenance. Although it is possible to produce nitrogen for reservoir pressure maintenance and CO2 for EOR completely independently, embodiments disclosed herein take advantage of the synergies that are possible when both nitrogen and CO2 are produced in an integrated process to accomplish the production of these gases at a much lower cost while also producing power.
Referring now to the figures, FIG. 1 illustrates a power generation system 100 configured to provide an improved post-combustion CO2 capture process using a combined-cycle arrangement. In at least one embodiment, the power generation system 100 can include a gas turbine system 102 that can be characterized as a closed Brayton cycle. In one embodiment, the gas turbine system 102 can have a first or main compressor 104 coupled to an expander 106 through a common shaft 108 or other mechanical, electrical, or other power coupling, thereby allowing a portion of the mechanical energy generated by the expander 106 to drive the compressor 104. The expander 106 may generate power for other uses as well. The gas turbine system 102 can be a standard gas turbine, where the main compressor 104 and expander 106 form the compressor and expander ends, respectively, of the standard gas turbine. In other embodiments, however, the main compressor 104 and expander 106 can be individualized components in a system 102.
The gas turbine system 102 can also include a combustion chamber 110 configured to combust a fuel stream 112 mixed with a compressed oxidant 114. In one or more embodiments, the fuel stream 112 can include any suitable hydrocarbon gas or liquid, such as natural gas, methane, ethane, naphtha, butane, propane, syngas, diesel, kerosene, aviation fuel, coal derived fuel, bio-fuel, oxygenated hydrocarbon feedstock, or combinations thereof. The compressed oxidant 114 can be derived from a second or inlet compressor 118 fluidly coupled to the combustion chamber 110 and adapted to compress a feed oxidant 120. In one or more embodiments, the feed oxidant 120 can include any suitable gas containing oxygen, such as air, oxygen-rich air, oxygen-depleted air, pure oxygen, or combinations thereof.
As will be described in more detail below, the combustion chamber 110 can also receive a compressed recycle stream 144, including a flue gas primarily having CO2 and nitrogen components. The compressed recycle stream 144 can be derived from the main compressor 104 and adapted to help facilitate the stoichiometric combustion of the compressed oxidant 114 and fuel 112, and also increase the CO2 concentration in the working fluid. A discharge stream 116 directed to the inlet of the expander 106 can be generated as a product of combustion of the fuel stream 112 and the compressed oxidant 114, in the presence of the compressed recycle stream 144. In at least one embodiment, the fuel stream 112 can be primarily natural gas, thereby generating a discharge 116 including volumetric portions of vaporized water, CO2, nitrogen, nitrogen oxides (NOx), and sulfur oxides (SOX). In some embodiments, a small portion of unburned fuel 112 or other compounds may also be present in the discharge 116 due to combustion equilibrium limitations. As the discharge stream 116 expands through the expander 106 it generates mechanical power to drive the main compressor 104, an electrical generator, or other facilities, and also produces a gaseous exhaust stream 122 having a heightened CO2 content.
The power generation system 100 can also include an exhaust gas recirculation (EGR) system 124. While the EGR system 124 illustrated in the figures incorporates various apparati, the illustrated configurations are representative only and any system that recirculates the exhaust gas 122 back to the main compressor may be used. In one or more embodiments, the EGR system 124 can include a heat recovery steam generator (HRSG) 126, or similar device, fluidly coupled to a steam gas turbine 128. In at least one embodiment, the combination of the HRSG 126 and the steam gas turbine 128 can be characterized as a closed Rankine cycle. In combination with the gas turbine system 102, the HRSG 126 and the steam gas turbine 128 can form part of a combined-cycle power generating plant, such as a natural gas combined-cycle (NGCC) plant. The gaseous exhaust stream 122 can be sent to the HRSG 126 in order to generate a stream of steam 130 and a cooled exhaust gas 132. In some embodiments, the steam 130 can be sent to the steam gas turbine 128 to generate additional electrical power.
FIG. 1 illustrates additional apparatus in the EGR system 124 that optionally may be incorporated in some implementations. The cooled exhaust gas 132 can be sent to at least one cooling unit 134 configured to reduce the temperature of the cooled exhaust gas 132 and generate a cooled recycle gas stream 140. In one or more embodiments, the cooling unit 134 can be a direct contact cooler, trim cooler, a mechanical refrigeration unit, or combinations thereof. The cooling unit 134 can also be configured to remove a portion of condensed water via a water dropout stream 138 which can, in at least one embodiment, be routed to the HRSG 126 via line 141 to provide a water source for the generation of additional steam 130. In one or more embodiments, the cooled recycle gas stream 140 can be directed to a boost compressor 142 (if required) fluidly coupled to the cooling unit 134. Cooling the cooled exhaust gas 132 in the cooling unit 134 can reduce the power required to compress the cooled recycle gas stream 140 in the boost compressor 142 or eliminate the need for it altogether.
The boost compressor 142 can be configured to increase the pressure of the cooled recycle gas stream 140 before it is introduced into the main compressor 104. As opposed to a conventional fan or blower system, the boost compressor 142 increases the overall density of the cooled recycle gas stream 140, thereby directing an increased mass flow rate for the same volumetric flow to the main compressor 104. Because the main compressor 104 is typically volume-flow limited, directing more mass flow through the main compressor 104 can result in a higher discharge pressure from the main compressor 104, thereby translating into a higher pressure ratio across the expander 106. A higher pressure ratio generated across the expander 106 can allow for higher inlet temperatures and, therefore, an increase in expander 106 power and efficiency. This can prove advantageous since the CO2-rich discharge 116 generally maintains a higher specific heat capacity. Accordingly, the cooling unit 134 and the boost compressor 142, when incorporated, may each be adapted to optimize or improve the operation of the gas turbine system 102.
The main compressor 104 can be configured to compress the cooled recycle gas stream 140 received from the EGR system 124, such as from the boost compressor 142, to a pressure nominally above the combustion chamber 110 pressure, thereby generating the compressed recycle stream 144. In at least one embodiment, a purge stream 146 can be tapped from the compressed recycle stream 144 and subsequently treated in a CO2 separator 148 to capture CO2 at an elevated pressure via line 150. The separated CO2 in line 150 can be used for sales, used in another process requiring carbon dioxide, and/or compressed and injected into a terrestrial reservoir for enhanced oil recovery (EOR), sequestration, or another purpose.
A residual stream 151, essentially depleted of CO2 and consisting primarily of nitrogen, can be derived from the CO2 separator 148. In one or more embodiments, the residual stream 151 can be expanded in a gas expander 152, such as a power-producing nitrogen expander, fluidly coupled to the CO2 separator 148. As depicted in FIGS. 1-3, the gas expander 152 can be optionally coupled to the inlet compressor 118 through a common shaft 154 or other mechanical, electrical, or other power coupling, thereby allowing a portion of the power generated by the gas expander 152 to drive the inlet compressor 118. After expansion in the gas expander 152, an exhaust gas 156, consisting primarily of nitrogen, can be vented to the atmosphere or implemented into other downstream applications known in the art. For example, the expanded nitrogen stream can be used in an evaporative cooling process configured to further reduce the temperature of the exhaust gas as generally described in the concurrently filed U.S. patent application entitled “Stoichiometric Combustion with Exhaust Gas Recirculation and Direct Contact Cooler,” the contents of which are hereby incorporated by reference to the extent not inconsistent with the present disclosure. In at least one embodiment, the combination of the gas expander 152, inlet compressor 118, and CO2 separator can be characterized as an open Brayton cycle, or the third power producing component of the system 100.
While the combination or coupling of the gas expander 152 and the inlet compressor 118 may resemble an open Brayton cycle, the gas expander 152, whether coupled or uncoupled from the inlet compressor 118, provides a third power producing component of the system 100. For example, the gas expander 152 can be used to provide power to other applications, and not directly coupled to the stoichiometric compressor 118. For example, there may be a substantial mismatch between the power generated by the expander 152 and the requirements of the compressor 118. In such cases, the expander 152 could be adapted to drive a smaller compressor (not shown) that demands less power (or to drive the inlet compressor 118 and one or more additional facilities).
In yet other embodiments, as will be discussed below with reference to FIG. 8, the gas expander 152 can be replaced with a downstream compressor 188 configured to compress the residual stream 151 and generate a compressed exhaust gas 190 suitable for injection into a reservoir for pressure maintenance or EOR applications.
The EGR system 124 as described herein can be implemented to achieve a higher concentration of CO2 in the working fluid of the power generation system 100, thereby allowing for more effective CO2 separation for subsequent sequestration, pressure maintenance, or EOR applications. For instance, embodiments disclosed herein can effectively increase the concentration of CO2 in the flue gas exhaust stream to about 10 vol % or higher. To accomplish this, the combustion chamber 110 can be adapted to stoichiometrically combust the incoming mixture of fuel 112 and compressed oxidant 114. In order to moderate the temperature of the stoichiometric combustion to meet expander 106 inlet temperature and component cooling requirements, a portion of the exhaust gas derived from the compressed recycle stream 144 can be injected into the combustion chamber 110 as a diluent. Thus, embodiments of the disclosure can essentially eliminate any excess oxygen from the working fluid while simultaneously increasing its CO2 composition. As such, the gaseous exhaust stream 122 can have less than about 3.0 vol % oxygen, or less than about 1.0 vol % oxygen, or less than about 0.1 vol % oxygen, or even less than about 0.001 vol % oxygen. In some implementations, the combustion chamber 110, or more particularly, the inlet streams to the combustion chamber may be controlled with a preference to substoichiometric combustion to further reduce the oxygen content of the gaseous exhaust stream 122.
The specifics of exemplary operation of the system 100 will now be discussed. As can be appreciated, specific temperatures and pressures achieved or experienced in the various components of any of the embodiments disclosed herein can change depending on, among other factors, the purity of the oxidant used and the specific makes and/or models of expanders, compressors, coolers, etc. Accordingly, it will be appreciated that the particular data described herein is for illustrative purposes only and should not be construed as the only interpretation thereof. For example, in one embodiment described herein, the inlet compressor 118 can be configured as a stoichiometric compressor that provides compressed oxidant 114 at pressures ranging between about 280 psia and about 300 psia. Also contemplated herein, however, is aeroderivative gas turbine technology, which can produce and consume pressures of up to about 750 psia and more.
The main compressor 104 can be configured to recycle and compress recycled exhaust gas into the compressed recycle stream 144 at a pressure nominally above or at the combustion chamber 110 pressure, and use a portion of that recycled exhaust gas as a diluent in the combustion chamber 110. Because amounts of diluent needed in the combustion chamber 110 can depend on the purity of the oxidant used for stoichiometric combustion or the model of expander 106, a ring of thermocouples and/or oxygen sensors (not shown) can be associated with the combustion chamber and/or the expander. For example, thermocouples and/or oxygen sensors may be disposed on the outlet of the combustion chamber 110, on the inlet to the expander 106, and/or on the outlet of the expander 106. In operation, the thermocouples and sensors can be adapted to determine the compositions and/or temperatures of one or more streams for use in determining the volume of exhaust gas required as diluent to cool the products of combustion to the required expander inlet temperature. Additionally or alternatively, the thermocouples and sensors may be adapted to determine the amount of oxidant to be injected into the combustion chamber 110. Thus, in response to the heat requirements detected by the thermocouples and the oxygen levels detected by the oxygen sensors, the volumetric mass flow of compressed recycle stream 144 and/or compressed oxidant 114 can be manipulated or controlled to match the demand. The volumetric mass flow rates may be controlled through any suitable flow control systems.
In at least one embodiment, a pressure drop of about 12-13 psia can be experienced across the combustion chamber 110 during stoichiometric combustion. Combustion of the fuel 112 and the compressed oxidant 114 can generate temperatures between about 2000° F. and about 3000° F. and pressures ranging from 250 psia to about 300 psia. Because of the increased mass flow and higher specific heat capacity of the CO2-rich working fluid derived from the compressed recycle stream 144, a higher pressure ratio can be achieved across the expander 106, thereby allowing for higher inlet temperatures and increased expander 106 power.
The gaseous exhaust stream 122 exiting the expander 106 can have a pressure at or near ambient. In at least one embodiment, the gaseous exhaust stream 122 can have a pressure of about 15.2 psia. The temperature of the gaseous exhaust stream 122 can range from about 1180° F. to about 1250° F. before passing through the HRSG 126 to generate steam in line 130 and a cooled exhaust gas 132. The cooled exhaust gas 132 can have a temperature ranging from about 190° F. to about 200° F. In one or more embodiments, the cooling unit 134 can reduce the temperature of the cooled exhaust gas 132 thereby generating the cooled recycle gas stream 140 having a temperature between about 32° F. and 120° F., depending primarily on wet bulb temperatures in specific locations and during specific seasons.
According to one or more embodiments, the boost compressor 142 can be configured to elevate the pressure of the cooled recycle gas stream 140 to a pressure ranging from about 17.1 psia to about 21 psia. As a result, the main compressor 104 receives and compresses a recycled flue gas working fluid with a higher density and increased mass flow, thereby allowing for a substantially higher discharge pressure while maintaining the same or similar pressure ratio. In at least one embodiment, the temperature of the compressed recycle stream 144 discharged from the main compressor 104 can be about 800° F., with a pressure of around 280 psia.
The following table provides testing results and performance estimations based on combined-cycle gas turbines, with and without the added benefit of a boost compressor 142, as described herein.
Triple-Cycle Performance Comparison
Recirc. Cycle Recirc. Cycle w/o Boost w/Boost Compressor Compressor
Power (MW) Gas Turbine Expander Power 1055 1150 Main Compressor 538 542 Fan or Boost Compressor 13 27 Inlet Compressor 283 315 Total Compression Power 835 883 Net Gas Turbine Power 216 261 Steam Turbine Net Power 395 407 Standard Machinery Net Power 611 668 Aux. Losses 13 15 Nitrogen Expander Power 156 181 Combined Cycle Power 598 653 Efficiency Fuel Rate (mBTU/hr) 5947 6322 Heat Rate (BTU/kWh) 9949 9680 Combined Cycle Eff. (% lhv) 34.3 35.2 CO2 Purge Pressure (psia) 280 308
As should be apparent from Table 1, embodiments including a boost compressor 142 can result in an increase in expander 106 power (i.e., “Gas Turbine Expander Power”) due to the increase in pressure ratios. Although the power demand for the main compressor 104 can increase, its increase is more than offset by the increase in power output of the expander 106, thereby resulting in an overall thermodynamic performance efficiency improvement of around 1% lhv (lower heated value).
Moreover, the addition of the boost compressor 142 can also increase the power output of the nitrogen expander 152 and the CO2 purge pressure in the purge stream 146 line. While the boost compressor 142 can increase the power output of the nitrogen expander 152, it can be seen in Table 1 that the nitrogen expander 152 is a significant contributor to the efficiency of the overall system 100 with or without the boost compressor.
An increase in purge pressure of the purge stream 146 can lead to improved solvent treating performance in the CO2 separator 148 due to the higher CO2 partial pressure. Such improvements can include, but are not limited to, a reduction in overall capital expenditures in the form of reduced equipment size for the solvent extraction process.
Referring now to FIG. 2, depicted is an alternative embodiment of the power generation system 100 of FIG. 1, embodied and described as system 200. As such, FIG. 2 may be best understood with reference to FIG. 1. Similar to the system 100 of FIG. 1, the system 200 of FIG. 2 includes a gas turbine system 102 coupled to or otherwise supported by an exhaust gas recirculation (EGR) system 124. The EGR system 124 in FIG. 2, however, can include an embodiment where the boost compressor 142 follows or may otherwise be fluidly coupled to the HRSG 126. As such, the cooled exhaust gas 132 can be compressed in the boost compressor 142 before being reduced in temperature in the cooling unit 134. Thus, the cooling unit 134 can serve as an aftercooler adapted to remove the heat of compression generated by the boost compressor 142. As with previously disclosed embodiments, the water dropout stream 138 may or may not be routed to the HRSG 126 to generate additional steam 130.
The cooled recycle gas stream 140 can then be directed to the main compressor 104 where it is further compressed, as discussed above, thereby generating the compressed recycle stream 144. As can be appreciated, cooling the cooled exhaust gas 132 in the cooling unit 134 after compression in the boost compressor 142 can reduce the amount of power required to compress the cooled recycle gas stream 140 to a predetermined pressure in the succeeding main compressor 104.
FIG. 3 depicts another embodiment of the low emission power generation system 100 of FIG. 1, embodied as system 300. As such, FIG. 3 may be best understood with reference to FIGS. 1 and 2. Similar to the systems 100, 200 described in FIGS. 1 and 2, respectively, the system 300 includes a gas turbine system 102 supported by or otherwise coupled to an EGR system 124. The EGR system 124 in FIG. 3, however, can include a first cooling unit 134 and a second cooling unit 136, having the boost compressor 142 fluidly coupled therebetween. As with previous embodiments, each cooling unit 134, 136 can be a direct contact cooler, trim cooler, or the like, as known in the art.
In one or more embodiments, the cooled exhaust gas 132 discharged from the HRSG 126 can be sent to the first cooling unit 134 to produce a condensed water dropout stream 138 and a cooled recycle gas stream 140. The cooled recycle gas stream 140 can be directed to the boost compressor 142 in order to boost the pressure of the cooled recycle gas stream 140, and then direct it to the second cooling unit 136. The second cooling unit 136 can serve as an aftercooler adapted to remove the heat of compression generated by the boost compressor 142, and also remove additional condensed water via a water dropout stream 143. In one or more embodiments, each water dropout stream 138, 143 may or may not be routed to the HRSG 126 to generate additional steam 130.
The cooled recycle gas stream 140 can then be introduced into the main compressor 104 to generate the compressed recycle stream 144 nominally above or at the combustion chamber 110 pressure. As can be appreciated, cooling the cooled exhaust gas 132 in the first cooling unit 134 can reduce the amount of power required to compress the cooled recycle gas stream 140 in the boost compressor 142. Moreover, further cooling exhaust in the second cooling unit 136 can reduce the amount of power required to compress the cooled recycle gas stream 140 to a predetermined pressure in the succeeding main compressor 104.
Referring now to FIG. 4, depicted is another embodiment of a low emission power generation system 400, similar in some respects to the system 300 of FIG. 3. As such, the system 400 of FIG. 4 may be best understood with reference to FIGS. 1 and 3. It should be noted, however, that individual embodiments, or combinations thereof disclosed with reference to FIGS. 1-3 can be implemented and/or omitted in conjunction with the system 400 of FIG. 4 without departing from the scope of the disclosure. For example, the specific facilities and equipment incorporated into the EGR system 124 may vary as described elsewhere herein.
As described above, the temperature of the compressed recycle stream 144 discharged from the main compressor 104 can be about 800° F., and exhibit pressures of around 280 psia. Consequently, the purge stream 146 tapped from the compressed recycle stream 144 can exhibit similar temperatures and pressures. It should be noted once again that specific temperatures and pressures will inevitably change depending on the specific make and model of expanders, compressors, coolers, etc. Since the pressure is much higher than those found in conventional natural gas combined-cycle (NGCC) systems with post-combustion CO2 recovery, it facilitates the use of a less energy-intensive gas treating process in the CO2 separator 148. For example, such elevated temperatures and pressures, in combination with a substantial lack of oxygen resulting from the stoichiometric combustion undertaken in the combustion chamber 110, can allow for the use of a hot potassium carbonate solvent to extract CO2 from the purge stream 146. In other embodiments, CO2 selective adsorbents can include, but are not limited to, monoethanolamine (“MEA”), diethanolamine (“DEA”), triethanolamie (“TEA”), potassium carbonate, methyldiethanolamine (“MDEA”), activated methyldiethanolamine (“aMDEA”), diglycolamine (“DGA”), diisopropanolamine (“DIPA”), piperazine (“PZ”), derivatives thereof, mixtures thereof, or any combination thereof. Other suitable adsorbents and techniques can include, but are not limited to, propylene carbonate physical adsorbent solvent as well as other alkyl carbonates, dimethyl ethers of polyethylene glycol of two to twelve glycol units (Selexol™ process), n-methyl-pyrrolidone, sulfolane, and use of the Sulfinol® Gas Treatment Process.
In one embodiment, the gas treating processes in the CO2 separator 148 can require the temperature of the purge stream 146 to be cooled to about 250° F.-300° F. To achieve this, the purge stream 146 can be channeled through a heat exchanger 158, such as a cross-exchange heat exchanger fluidly coupled to the residual stream 151. In at least one embodiment, extracting CO2 from the purge stream 146 in the CO2 separator 148 can leave a nitrogen-rich residual stream 151 at or near the elevated pressure of the purge stream 146 and at a temperature of about 150° F. In one embodiment, the heat energy associated with cooling the purge stream 146 can be extracted via the heat exchanger 158 and used to re-heat the residual stream 151, thereby generating a heated nitrogen vapor 160 having a temperature of about 750° F. and a pressure of around 270-280 psia. While heat exchange with the purge stream 146 is one manner of heating the residual stream, other methods are within the scope of the present disclosure. For example, in one or more embodiments supplemental heating of stream 151 may be done by using the HRSG 126 to supply heat as well as well as to generate steam 130. Other exemplary methods are described herein and should not be considered an exhaustive listing of available methods to heat the residual stream 151.
In one or more embodiments, the heated nitrogen vapor 160 can then be expanded through the gas expander 152. Accordingly, cross-exchanging the heat in the heat exchanger 158 can be configured to capture a substantial amount of compression energy derived from the main compressor 104 and use it to maximize the power extracted from the gas expander 152, and optionally power the stoichiometric inlet compressor 118. In at least one embodiment, the exhaust gas 156, consisting primarily of nitrogen at atmospheric pressure, can be harmlessly vented to the atmosphere or implemented into other downstream applications known in the art. Exemplary downstream applications, such as evaporative cooling processes, are described in the concurrently filed U.S. patent application entitled “Stoichiometric Combustion with Exhaust Gas-Recirculation and Direct Contact Cooler,” as stated above.
During start-up of the system 400 and during normal operation when the gas expander 152 may be unable to supply all the required power to operate the inlet compressor 118, at least one motor 162, such as an electric motor, can be used synergistically with the gas expander 152. For instance, the motor(s) 162 can be sensibly sized such that during normal operation of the system 400, the motor(s) 162 can be configured to supply the power short-fall from the gas expander 152. Additionally or alternatively, there may be times during operation when the gas expander 152 produces more energy than required by the inlet compressor 118. In some implementations, the at least one motor 162 may be a motor/generator system that may be selectively configured to provide power, such as from the electric grid, to the compressor or to generate electricity from the power generated by the turbine 152.
Referring now to FIG. 5, depicted is another embodiment of a low emission power generation system 500, similar in some respects to the system 400 of FIG. 4. As such, the entire system 500 of FIG. 5 will not be described in detail but may be best understood with reference to FIGS. 1, 3, and 4. It should be noted that any embodiment disclosed with reference to FIGS. 1-4 can be implemented individually or in combination into the system 500, without departing from the scope of the disclosure.
In an embodiment, once the purge stream 146 is tapped from the compressed recycle stream 144, its temperature can be increased by a catalytic process undertaken in a catalysis apparatus 164. In operation, the catalysis apparatus 164 can be configured to reduce the oxygen and/or carbon monoxide content in the purge stream, and convert it into residual CO2 and heat. The catalysis apparatus 164 can be a single device or a plurality of devices in parallel, series, or a combination of parallel and series. In one embodiment, the catalysis apparatus 164 can be a small device requiring only a small amount of power to operate. One exemplary catalysis apparatus 164 can include an oxygen reduction catalyst that is normally used in a HRSG to meet emissions requirements. Such a system generally is not designed to remove large amounts of oxygen, but if significant amounts of oxygen remain in compressed recycle stream 144, the purge stream 146 can be recycled through the catalysis apparatus 164 more than once before further processing or use, e.g., compression and injection for enhanced oil recovery (EOR), CO2 separation, etc.
Moreover, any residual hydrocarbons in the purge stream 146 can also be combusted in the catalysis apparatus 164. In at least one embodiment, the temperature of the purge stream 146 can be increased from about 785° F. to about 825° F. by the complete catalytic conversion of about 1200 ppm oxygen present in the purge stream 146. Illustrative catalysts that can be used in the catalysis apparatus 164 can include, but are not limited to, Nickel, Platinum, Rhodium, Ruthenium, Palladium, or derivatives thereof, mixtures thereof, any combination thereof. This increase in heat content can be introduced into the heat exchanger 158 and cross-exchanged with the nitrogen-rich residual stream 151, thereby resulting in a higher temperature of heated nitrogen vapor 160 and facilitating a more effective and powerful expansion process in the gas expander 152.
As still further enhancements to the triple-cycle system including the gas expander 152, in one or more embodiments, water can be injected via line 166 into the heated nitrogen vapor 160 to increase the mass throughput of the gas expander 152 and consequently increase the power generated. The water can be treated atomized water or steam. In at least one embodiment, the supplementary power provided by the injection of atomized water or steam can increase the power output from about 169 MW to about 181 MW. As can be appreciated, the power output will generally be dependent on the make and model of the gas expander. It should be noted that injecting atomized water or steam via line 166 into the heated nitrogen vapor 160 in order to increase the mass flow through the gas expander 152 can be implemented into any of the embodiments disclosed herein, without departing from the scope of the disclosure.
Referring to FIG. 6, depicted is another embodiment of a low emission power generation system 600, similar to the system 500 of FIG. 5. As such, the entire system 600 will not be described in detail but may be best understood with reference to FIG. 5. In one embodiment, the system 600 can include an additional stoichiometric combustion chamber 168 disposed prior to the gas expander 152. The combustion chamber 168 can be configured to stoichiometrically combust a combination of fuel 170 and compressed oxidant 172, much like the combustion chamber 110 described above, in order to generate a discharge stream 174 at an elevated temperature and pressure. In one embodiment, the fuel 170 and the compressed oxidant 172 can be derived from the same source as the fuel 112 and the compressed oxidant 114, respectively, that are fed into the first combustion chamber 110. In implementations incorporating the additional combustion chamber 168, the heat exchanger 158 may cool the purge stream through other means, such as by heating one or more other streams in the system 600 or elsewhere. For example, the heat exchanger on the purge stream may provide additional heat to the HRSG or to a reforming process.
In other embodiments, especially embodiments where zero CO2 emissions is desired or required, the fuel 170 can consist primarily of hydrogen. In at least one embodiment, the hydrogen fuel can be produced by reforming methane in the HRSG 126, or a separate HRSG (not shown). After the reformation of the methane and a water gas shift, the CO2 in the hydrogen product stream can be removed in an absorption tower (not shown), for example, in the CO2 separator 148. The hydrogen could then be blended with some of the nitrogen in the heated nitrogen vapor 160 stream within the combustion chamber 168 to make an acceptable gas turbine fuel.
The heated nitrogen vapor 160 discharged from the heat exchanger 158, or discharged from the CO2 separator 148, can serve as a diluent configured to moderate the temperature of combustion and the discharge stream 174. In at least one embodiment, the discharge stream 174 exiting the combustion chamber 168 can have a temperature of about 2500° F. before being expanded in the gas expander to create mechanical power. As will be appreciated, the combination of the gas expander 152, combustion chamber 168, and inlet compressor 118 can be characterized as a separate standard gas turbine system, where the inlet compressor 118 becomes the compressor end and the gas expander 152 becomes the expander end of the gas turbine.
In one or more embodiments, the exhaust gas 156 can have a temperature of about 1100° F. In at least one embodiment, the exhaust gas 156 can be directed to the HRSG 126 to recover the heat as power in the steam gas turbine 128. In other embodiments, the exhaust gas 156 can be directed to an external HRSG and steam gas turbine (not shown) to generate power for other applications. In any event, the nitrogen-rich residual stream 151 may be disposed of in any of the manners discussed herein, such as via nitrogen vent, via sequestration, EOR, or pressure maintenance operations, etc., after passing through the expander 152.
Referring now to FIG. 7, depicted is another embodiment of a low emission power generation system 700, similar to the system 600 of FIG. 6. As such, the entire system 700 of FIG. 7 will not be described in detail but may be best understood with reference to FIG. 6 and its accompanying description. Instead of utilizing a separate inlet compressor 118 and nitrogen expander 152 (see FIGS. 1-6), the system 700 as depicted in FIG. 7 can include a second gas turbine system 702, having a second compressor 176 and second expander 178. In one or more embodiments, the second compressor 176 can receive and compress a second feed oxidant 180. Similar to the feed oxidant 120 shown and described above in FIGS. 1-6, the second feed oxidant 180 can include any suitable gas containing oxygen, such as air, oxygen-rich air, or combinations thereof. The second compressor 176 can be configured to compress the second feed oxidant 180 and generate a second compressed oxidant 182. As depicted, the compressed oxidant 114 required for the combustion chamber 110 can be supplied or extracted from the second compressed oxidant 182 stream and serve the same function as generally described above.
In operation, the combustion chamber 168 can be configured to stoichiometrically combust a combination of the fuel 170 and the second compressed oxidant 182 in order to generate a discharge stream 174 at an elevated temperature and pressure. In one or more embodiments, the nitrogen vapor 160 from the heat exchanger 158 or the residual stream from the CO2 separator 148 can be utilized as a diluent configured to moderate the temperature of combustion in the second combustion chamber 168. In one embodiment, the fuel 170 can be derived from the same source as the fuel 112 fed into the first combustion chamber 110, such as a hydrocarbon fuel. In other embodiments where zero CO2 emissions is desired or required, the fuel 170 can consist primarily of hydrogen, as generally described above with reference to FIG. 6.
If a hydrocarbon fuel is used, then CO2 emissions will naturally result. However, because of the use of a largely-pure nitrogen stream as a diluent, the resulting CO2 emissions will be significantly less than when compared with a conventional NGCC power plant. For example, in one embodiment, the CO2 emissions resulting from the system 700 will only be about 80 lbs/MWhr as compared with about 400 lbs/MWhr for a conventional NGCC power plant. In one or more embodiments, the exhaust gas 156 from the second expander 178 can have a temperature of about 1100° F. In at least one embodiment, the exhaust gas 156 can be directed to a second HRSG 184 to recover the heat as power in a separate steam gas turbine 186. In alternative embodiments, however, the exhaust gas 156 can be directed to the first HRSG 126 to recover the heat as power in the steam gas turbine 128. Here again, it can be understood that exhaust gas 156 may be vented or otherwise used in hydrocarbon recovery operations (not shown) as described above after passing through the second HRSG 184.
As can be appreciated, the system 700 of FIG. 7 can allow a commercially-available gas turbine to be utilized instead of undergoing costly upgrades to obtain a custom-built air compressor and a custom-built expander. The system 700 can also produce more net power at a higher efficiency because the inlet temperature of the second expander 178 can reach temperatures around 2500° F.
Referring now to FIG. 8, depicted is another embodiment of a low emission power generation system 800, similar to the system 300 of FIG. 3. As such, the entire system 800 of FIG. 8 will not be described in detail but may be best understood with reference to FIGS. 1 and 3. It should be noted, however, that embodiments disclosed with reference to FIGS. 1-6 can be implemented individually or in combination with the system 800 of FIG. 8 without departing from the scope of the disclosure. In an exemplary embodiment, the residual stream 151, consisting primarily of nitrogen derived from the CO2 separator 148, can be channeled to a downstream compressor 188. The downstream compressor 188 can be configured to compress the residual stream 151 and generate a compressed exhaust gas 190 having a pressure of, for example, about 3400 psi or pressures otherwise suitable for injection into a reservoir for pressure maintenance applications.
Compressing the residual stream 151 with the downstream compressor 188 may prove advantageous in applications where methane gas is typically reinjected into hydrocarbon wells to maintain well pressures. According to embodiments disclosed herein, nitrogen can instead be injected into hydrocarbon wells and the residual methane gas can either be sold or otherwise used as a fuel in related applications, such as providing fuel for the fuel streams 112, 170 (see FIGS. 6 and 7).
With continuing reference to FIGS. 5-7, the following table provides testing results and performance estimations based on systems without an expansion cycle (e.g., system 800 of FIG. 8), systems without additional firing in the combustion chamber 168 (e.g., system 500 of FIG. 5), and systems with additional firing in the combustion chamber 168 (e.g., systems 600, 700 of FIGS. 6 and 7, respectively). The data reflects a methane fuel 170 being fired for combustion.
Cycle - No Cycle w/o Cycle w/ Expansion Firing Firing
Power (MW) Gas Turbine Expander Power 1150 1150 1150 Main Compressor 542 542 542 Fan or Boost Compressor 27 27 27 Inlet Compressor 315 251 601 Total Compression Power 883 883 1170 Net Gas Turbine Power 258 258 −32 Steam Turbine Net Power 407 339 339 Standard Machinery Net Power 665 597 307 Aux. Losses 15 13 7 Nitrogen Expander power 0 203 1067 Supp. Steam Turbine Power 0 0 303 Combined Cycle Power 650 787 1670 Efficiency Fuel Rate (Mbtu/hr) 6322 6322 11973 Heat Rate (BTU/kWh) 9727 8037 7167 Combined Cycle Eff. (% lhv) 35.1 42.5 47.6 CO2 Purge Pressure (psia) 308 308 308
As should be apparent from Table 2, embodiments with firing in the combustion chamber 168 can result in a significantly higher combined-cycle power output; almost double the power output when compared with embodiments not implementing firing in the combustion chamber 168. Moreover, the overall thermodynamic performance efficiency exhibits a substantial uplift or improvement of around 3.3% lhv (lower heated value) for systems incorporating firing as disclosed herein, as opposed to embodiments not implementing such firing techniques.
a CO2 separator fluidly coupled to the compressed recycle stream via a purge stream; and
a gas expander fluidly coupled to the CO2 separator via a residual stream consisting primarily of nitrogen-rich gas derived from the CO2 separator.
extracting a portion of the compressed recycle stream to a CO2 separator via a purge stream, the CO2 separator being fluidly coupled to a gas expander via a residual stream derived from the CO2 separator and consisting primarily of nitrogen-rich gas; and
23. The method of claim 22, further comprising moderating the temperature of the second discharge stream with the residual stream discharged from the CO2 separator.
a first gas turbine system, comprising: a first compressor configured to receive and compress a recycled exhaust gas and provide a first compressed recycle stream; a first combustion chamber configured to receive the first compressed recycle stream, a first compressed oxidant, and a first fuel stream, the first combustion chamber being adapted to stoichiometrically combust the first fuel stream and first compressed oxidant, wherein the first compressed recycle stream serves as a diluent to moderate combustion temperatures; and a first expander coupled to the first compressor and configured to receive a first discharge from the first combustion chamber and generate the recycled exhaust gas and at least partially drive the first compressor;
a purge stream taken from the compressed recycle stream and treated in a CO2 separator to provide a CO2 stream and a residual stream, the residual stream substantially comprising a nitrogen gas; and
a second gas turbine system fluidly coupled to the first gas turbine system via the purge stream, the second gas turbine system comprising: a second compressor configured to receive and compress a feed oxidant and generate a second compressed oxidant, the first compressed oxidant being derived at least partially from the second compressed oxidant; a second combustion chamber configured to receive the second compressed oxidant, the nitrogen gas from the residual stream, and a second fuel stream, the second combustion chamber being adapted to stoichiometrically combust the second fuel stream and second compressed oxidant, wherein the nitrogen gas serves as a diluent to moderate combustion temperatures; and a second expander coupled to the second compressor and configured to receive a second discharge from the second combustion chamber and generate an exhaust and at least partially drive the second compressor.
a gas turbine system having a first combustion chamber configured to stoichiometrically combust a compressed oxidant and a fuel in the presence of a compressed recycle stream, wherein the combustion chamber provides a discharge stream to an expander in order to generate a gaseous exhaust stream and at least partially drive a first compressor;
an exhaust gas recirculation system having at least one boost compressor configured to receive and boost the pressure of the gaseous exhaust stream before directing a cooled recycle gas into the first compressor, wherein the first compressor compresses the cooled recycle gas and thereby generates the compressed recycle stream, the compressed recycle stream acting as a diluent configured to moderate the temperature of the discharge stream;
a downstream compressor fluidly coupled to the CO2 separator via a residual stream derived from the CO2 separator and consisting primarily of nitrogen-rich gas.
Publication number: 20130104563
Patent Grant number: 9903271
Inventors: Russell H. Oelfke (Houston, TX), Moses Minta (Missouri City, TX)
Application Number: 13/702,538
Current U.S. Class: Having Power Output Control (60/773); With Combustible Gas Generator (60/39.12)
International Classification: F02C 3/02 (20060101);