Carbon capture with power generation

• US 8,850,826 B2
• Filed: 11/22/2010
• Issued: 10/07/2014
• Est. Priority Date: 11/20/2009
• Status: Active Grant

• Current Assignee: EGT Enterprise, Inc.
• Original Assignee: EGT Enterprise, Inc.
• Inventors: Ennis, Bernard P.
• Primary Examiner(s): Rodriguez, William H
• Assistant Examiner(s): MEADE, LORNE EDWARD
• Application Number:
  US12/951,541
• Publication Number:
  US 20110120137A1
• Time in Patent Office: 1,415 Days
• Field of Search: 60/394.65, 607/80, 607/83, 607/84, 429/416, 429/502, 429/503, 429/505
• US Class Current: 60/780
• CPC Class Codes: F02C 7/224 Heating fuel before feeding to the burner
• CPC Class Codes: H01M 8/04082 Arrangements for control of reactant parameters, e.g. pressure or concentration
• CPC Class Codes: H01M 8/0643 Gasification of solid fuel
• CPC Class Codes: H01M 8/225 Fuel cells in which the fuel is based on materials comprising particulate active material in the form of a suspension, a dispersion, a fluidised bed or a paste
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A gas turbine power generation system having a carbon production apparatus and a carbon fuel cell to generate electricity. The carbon production apparatus is functionally connected to the fuel cell to provide carbon to the fuel cell to generate electricity. The system is configured to power the carbon production apparatus with a portion of the electricity generated from the fuel cell.

Claims

1. A power generation system comprising:

a carbon production apparatus in the form of an Electric Reaction Technology system having electric resistance heaters to decompose a hydrocarbon gas to hydrogen gas and carbon solids in an oxygen-free and oxidant-free environment, and without net production of carbon monoxide and carbon dioxide;

a separator separating a combined flow of the hydrogen gas and carbon solids from the Electric Reaction Technology system into a hydrogen qas stream and a carbon solids stream;

a direct carbon fuel cell to generate electricity and a carbon dioxide gas stream;

the separator functionally connected to the direct carbon fuel cell to provide the carbon solids stream to the direct carbon fuel cell to generate electricity;

wherein the power generation system is configured to power the Electric Reaction Technology system with a portion of the electricity generated from the direct carbon fuel cell;

a gas turbine system having a combustor; and

a heat exchanger fluidly connected to the separator, the direct carbon fuel cell, and the combustor to heat the hydrogen gas stream using the carbon dioxide gas stream, wherein the power generation system is configured so the heated hydrogen gas stream from the heat exchanger is input as fuel to the combustor.

2. The power generation system of claim 1 configured to combine the generated electricity with intermittent electricity from one or more additional sources to produce optimum dispatch.

3. The power generation system of claim 1 wherein the Electric Reaction Technology system comprises:

one or more heating zones, wherein each heating zone comprises one or more heating stations and each heating station comprises one or more heating screens followed by a final near-equilibrium attainment zone without additional heat input;

an inlet into a first of the one or more heating zones for input of the hydrocarbon gas from which the carbon solids will be formed;

a finishing station for cooling and removal of the carbon solids;

an outlet for the output of the hydrogen gas; and

an outlet for the output of the carbon solids.

4. The power generation system of claim 1 further comprising:

the gas turbine system having a compressor;

wherein the power generation system is configured so oxygen-depleted air released from the direct carbon fuel cell enters the combustor and serves as a diluent/coolant, thereby reducing the load on the compressor.

5. The power generation system of claim 1 further comprising a carbon dioxide source wherein the power generation system is configured so the carbon solids stream produced by the carbon production apparatus is carried by carbon dioxide from the carbon dioxide source to the direct carbon fuel cell.

6. The power generation system of claim 1 further comprising a combined cycle gas turbine system.

7. The power generation system of claim 1 further comprising a simple cycle gas turbine system.

8. The power generation system of claim 1 further comprising:

the gas turbine system having a steam turbine;

wherein the power generation system is configured so heat released from the direct carbon fuel cell is used as a supplemental source of steam for the steam turbine.

9. The power generation system of claim 1 further comprising:

the gas turbine system having a first compressor and

a second compressor, wherein the first compressor provides air to the direct carbon fuel cell and the second compressor provides air to the combustor.

10. The power generation system of claim 1 further comprising:

the gas turbine system having a compressor,

wherein the compressor provides air to the direct carbon fuel cell and to the combustor.

11. The power generation system of claim 1 wherein the direct carbon fuel cell is configured to run at greater than atmospheric pressure.

12. The power generation system of claim 11 wherein the direct carbon fuel cell is configured to run in a pressure range of about 150 psig to about 450 psig.

13. The power generation system of claim 1 further comprising:

a carbon solids storage component, a hydrogen gas storage component or both; and

one or more machine readable storage media containing an executable code configured to utilize the stored carbon solids and/or hydrogen gas to generate power on a variable basis.

14. The power generation system of claim 13 wherein the variable basis is dependent on one or both of electricity rates and fuel prices.

15. The power generation system of claim 1 having a compressor configured to:

compress air;

recover at least some of the heat generated by compressing the air; and

utilize at least some of the recovered heat in the direct carbon fuel cell to increase electricity production.

16. The power generation system of claim 1 further comprising:

the gas turbine system having a gas turbine and an air compressor that are independently controllable.

17. A method of reconfiguring a gas turbine power generation system to capture carbon comprising:

providing a carbon production apparatus in the form of an Electric Reaction Technology system having electric resistance heaters to decompose hydrocarbon gas to hydrogen gas and carbon solids in an oxygen-free and oxidant-free environment, and without net production of carbon monoxide and carbon dioxide;

separating a combined flow of the hydrogen gas and carbon solids from the Electric Reaction Technology system into a hydrogen gas stream and a carbon solids stream in a separator;

providing a direct carbon fuel cell;

configuring the gas turbine power generation system, carbon production apparatus and direct carbon fuel cell such that carbon from the carbon solids stream is used by the direct carbon fuel cell to generate electricity and a carbon dioxide qas stream;

using a portion of the generated electricity to power the Electric Reaction Technology system;

heating a portion of the hydrogen gas stream in a heat exchanger using the carbon dioxide gas stream as a heat source; and

fueling the gas turbine power generation system with the heated portion of the hydrogen gas stream.

18. The method of claim 17 further comprising configuring the gas turbine power generation system to store the carbon solids stream and/or the hydrogen gas stream and utilize the carbon solids stream and/or the hydrogen gas stream to generate power on a variable basis dependent on one or both of electricity rates and fuel prices.

19. The method of claim 17 further comprising:

combining the direct carbon fuel cell generated electricity with intermittent electricity from one or more additional sources to produce optimum dispatch.

20. The method of claim 17 further comprising:

reconfiguring the gas turbine power generation system so the hydrogen gas from the carbon production apparatus is input as a fuel to a combustor of the gas turbine system.

21. The method of claim 17 wherein the gas turbine power generation system has a compressor and combustor and the method comprises:

directing oxygen-depleted air released from the direct carbon fuel cell into the combustor as a diluent/coolant, thereby reducing the load on the compressor.

23. The method of claim 17 wherein the gas turbine power generation system has a steam turbine and the method comprises;

using heat released from the direct carbon fuel cell as a supplemental source of steam for the steam turbine.

24. The method of claim 17 wherein the gas turbine power generation system has a combustor, a first compressor and a second compressor, and the method comprises:

providing air to the direct carbon fuel cell from the first compressor; and

providing air to the combustor from the second compressor.

25. The method of claim 17 wherein the gas turbine power generation system has a gas turbine and an air compressor, and the method comprises:

independently controlling the gas turbine and the air compressor.

22. The method of claim comprising:

providing a carbon dioxide source;

carrying, by carbon dioxide, the carbon produced by the carbon production apparatus from the separator to the direct carbon fuel cell.

26. A method of reconfiguring a gas turbine power generation system to capture carbon comprising:

providing a carbon production apparatus in the form of a plasma system to decompose hydrocarbons to hydrogen gas and carbon solids in an oxygen-free and oxidant-free environment, and without net production of carbon monoxide and carbon dioxide;

separating a combined flow of the hydrogen gas and carbon solids from the plasma system into a hydrogen gas stream and a carbon solids stream;

providing a direct carbon fuel cell;

configuring the gas turbine power generation system, carbon production apparatus and direct carbon fuel cell such that carbon from the carbon solids stream is used by the direct carbon fuel cell to generate electricity and a carbon dioxide gas stream;

using a portion of the generated electricity to power the plasma system;

heating a portion of the hydrogen gas stream in a heat exchanger using the carbon dioxide gas stream as a heat source; and

fueling the gas turbine power generation system using the heated portion of the hydrogen gas stream.

27. A power generation system comprising:

a carbon production apparatus in the form of an plasma system to decompose hydrocarbon gas to hydrogen gas and carbon solids in an oxygen-free and oxidant-free environment, and without net production of carbon monoxide and carbon dioxide;

a separator separating a combined flow of the hydrogen gas and carbon solids from the plasma system into a hydrogen gas stream and a carbon solids stream;

a direct carbon fuel cell to generate electricity and a carbon dioxide gas stream;

the separator functionally connected to the direct carbon fuel cell to provide the carbon solids stream to the direct carbon fuel cell to generate electricity;

wherein the power generation system is configured to power the plasma system with a portion of the electricity generated from the direct carbon fuel cell;

a gas turbine system having a combustor; and

a heat exchanger fluidly connected to the separator, the direct carbon fuel cell, and the combustor to heat the hydrogen gas stream using the carbon dioxide gas stream, wherein the power generation system is configured so the heated hydrogen gas stream from the heat exchanger is input as fuel to the combustor.