Low emission power generation systems and methods

• US 9,732,675 B2
• Filed: 06/09/2011
• Issued: 08/15/2017
• Est. Priority Date: 07/02/2010
• Status: Expired due to Fees

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Minta, Moses, Oelfke, Russell H.
• Primary Examiner(s): Sung, Gerald L
• Assistant Examiner(s): Burke, Thomas
• Application Number:
  US13/702,541
• Publication Number:
  US 20130086916A1
• Time in Patent Office: 2,259 Days
• CPC Class Codes: F02C 3/34 with recycling of part of the working fluid, i.e. semi-closed cycles with combustion products in the closed part of the cycle
• CPC Class Codes: F02C 6/003 Gas-turbine plants with heaters between turbine stages
• CPC Class Codes: F02C 7/22 Fuel supply systems
• CPC Class Codes: F05D 2260/61 Removal of CO2 removal of CO2 from waste gases B01D53/62
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]

Abstract

Methods and systems for CO₂ separation for low emission power generation in combined-cycle power plants are provided. One system includes a gas turbine system that stoichiometrically combusts a fuel and an oxidant in the presence of a compressed recycle stream to provide mechanical power and a gaseous exhaust. The compressed recycle stream acts as a diluent to moderate the temperature of the combustion process. A boost compressor can boost the pressure of the gaseous exhaust before being compressed into the compressed recycle stream. A purge stream is tapped off from the compressed recycle stream and directed to a CO₂ separator configured to absorb CO₂ from the purge stream using a potassium carbonate solvent.

Claims

1. An integrated CO₂ separation system, comprising:

a gas turbine system having a combustion chamber configured to substantially stoichiometrically combust a compressed oxidant and a fuel, where the compressed oxidant is air, oxygen-rich air, oxygen-depleted air, or combinations thereof;

a combustion temperature control system configured to inject at least a portion of a compressed recycle stream into the combustion chamber to generate a discharge stream and to act as a diluent to control the temperature of the discharge stream, wherein the compressed recycle stream is injected into the combustion chamber independent of the compressed oxidant;

an expander configured to expand the discharge stream to generate a gaseous exhaust stream and at least partially drive a main compressor;

an exhaust gas recirculation system having a boost compressor and one or more cooling units configured to provide a cooled recycle gas having a water component and a gaseous component to the main compressor, wherein the main compressor (i) receives substantially all of the gaseous component of the cooled recycle gas that passes through the boost compressor and (ii) compresses the cooled recycle gas and generates the compressed recycle stream, a portion of which is directed to the combustion chamber and a portion of which provides a purge stream; and

a CO₂ separator fluidly coupled to the purge stream, the CO₂ separator comprising;

an absorber column configured to receive the purge stream and circulate a potassium carbonate solvent therein to absorb CO₂ in the purge stream, wherein the absorber column discharges a nitrogen-rich residual stream and a bicarbonate solvent solution;

a first valve fluidly coupled to the absorber column and configured to flash the bicarbonate solvent solution to a lower pressure, thereby generating a reduced-pressure solution;

a separator fluidly coupled to the first valve and configured to receive the reduced-pressure solution and remove a first portion of CO₂ therefrom;

a second valve fluidly coupled to the separator and configured to receive a remaining portion of the reduced-pressure solution and flash the remaining portion to a near-atmospheric pressure, thereby generating a near-atmospheric bicarbonate solvent solution;

a regeneration column fluidly coupled to the second valve and configured to receive and boil the near-atmospheric bicarbonate solvent solution to remove a CO₂ and water mixture therefrom, thereby producing a regenerated potassium carbonate solvent to be recirculated back to the absorber column; and

a condenser fluidly coupled to the regeneration column and configured to receive and separate a second portion of CO₂ from the CO₂ and water mixture removed from the near-atmospheric bicarbonate solvent solution;

wherein the pressure of the first portion of CO₂ is higher than the pressure of the second portion of CO₂ and the first portion and the second portion of CO₂ are separately directed to a downstream compression system.

2. The system of claim 1, wherein the temperature of the purge stream is about 800°

F., and the pressure of the purge stream is about 280 psia.

3. The system of claim 2, further comprising a heat exchanger associated with the purge stream, wherein the heat exchanger is a cross-exchange heat exchanger configured to reduce the temperature of the purge stream to between 250°

F. and 300°

F.

4. The system of claim 1, wherein the regeneration column operates at a pressure of about 3 psig.

5. The system of claim 1, further comprising a reboiler fluidly coupled to the regeneration column and configured to receive and heat a portion of the regenerated potassium carbonate solvent and produce a heated regenerated potassium carbonate solvent.

6. The system of claim 5, wherein the reboiler is configured to recirculate the heated regenerated potassium carbonate solvent back into the regeneration column to produce steam for boiling the bicarbonate solvent solution.

7. The system of claim 1, wherein the second portion of CO₂ is directed to a first stage of the downstream compression system and the first portion of CO₂ is directed to an intermediate stage of the downstream compression system.

8. The system of claim 1, wherein a portion of the water separated from the CO₂ and water mixture is pumped back into the regeneration column to create steam.

9. The system of claim 1, wherein a portion of the bicarbonate solvent solution is withdrawn from the regeneration column prior to complete solvent regeneration, and recirculated and fed low into the absorber column.

10. The system of claim 9, wherein 50% or more of a total amount of bicarbonate solvent solution is withdrawn from the regeneration column prior to complete solvent regeneration.

11. An integrated CO₂ separation system, comprising:

a gas turbine system having a combustion chamber configured to substantially stoichiometrically combust a compressed oxidant and a fuel, where the compressed oxidant is air, oxygen-rich air, oxygen-depleted air, or combinations thereof;

a combustion temperature control system configured to inject at least a portion of a compressed recycle stream into the combustion chamber to generate a discharge stream in order to expand the discharge stream in an expander, thereby generating a gaseous exhaust stream and at least partially driving a main compressor, wherein the compressed recycle stream acts as a diluent configured to moderate the temperature of the discharge stream, and wherein the compressed recycle stream is injected into the combustion chamber independent of the compressed oxidant;

at least one oxygen sensor disposed on one of an outlet or an inlet of the expander or on an outlet of the combustion chamber and operatively connected to a flow control system, wherein the at least one oxygen sensor determines a preferred amount of the oxidant to be injected into the combustion chamber by the flow control system;

an exhaust gas recirculation system having a boost compressor and one or more cooling units fluidly coupled to the boost compressor, the boost compressor being configured to receive and boost the pressure of the gaseous exhaust stream having a gaseous component and a water component and the one or more cooling units being configured to cool the gaseous exhaust stream and provide a cooled recycle gas to the main compressor, wherein the main compressor receives substantially all of the gaseous component of the cooled recycle gas that passes through the boost compressor, compresses the cooled recycle gas and generates the compressed recycle stream;

a purge stream fluidly coupled to the compressed recycle stream and having a heat exchanger configured to reduce the temperature of the purge stream and generate a cooled purge stream; and

a CO₂ separator fluidly coupled to the heat exchanger, the CO₂ separator comprising;

an absorber column configured to receive the cooled purge stream and circulate a potassium carbonate solvent therein to absorb CO₂ in the cooled purge stream, wherein the absorber column discharges a nitrogen-rich residual stream and a bicarbonate solvent solution;

a first valve fluidly coupled to the absorber column and configured to flash the bicarbonate solvent solution to a lower pressure, thereby generating a reduced-pressure solution;

a separator fluidly coupled to the first valve and configured to receive the reduced-pressure solution and remove a first portion of CO₂ therefrom to be injected into an inner stage of a downstream compression system;

a second valve fluidly coupled to the separator and configured to receive remaining portions of the reduced-pressure solution and flash the remaining portions to a near-atmospheric pressure, thereby generating a near-atmospheric bicarbonate solvent solution;

a regeneration column fluidly coupled to the second valve and configured to receive and boil the near-atmospheric bicarbonate solvent solution to remove a second portion of CO₂ and water, thereby producing a regenerated potassium carbonate solvent to be recirculated back to the absorber column; and

a condenser fluidly coupled to the regeneration column and configured to receive and separate a second portion of CO₂ from the CO₂ and water mixture removed from the near-atmospheric bicarbonate solvent solution;

wherein the pressure of the first portion of CO₂ is higher than the pressure of the second portion of CO₂ and the first portion and the second portion of CO₂ are separately directed to a downstream compression system.

12. The system of claim 11, wherein the temperature of the purge stream is about 800°

F., and the pressure of the purge stream is about 280 psia.

13. The system of claim 12, wherein the heat exchanger is a cross-exchange heat exchanger configured to reduce the temperature of the purge stream to between 250°

F. and 300°

F.

14. The system of claim 13, further comprising a high pressure cooling unit configured to cool the first portion of CO₂ prior to injection into the inner stage of the downstream compression system.

15. The system of claim 13, wherein the second portion of CO₂ is directed to a first stage of the downstream compression system and the first portion of CO₂ is directed to an intermediate stage of the downstream compression system.

16. A method of separating CO₂, comprising:

substantially stoichiometrically combusting a compressed oxidant and a fuel in a combustion chamber, where the compressed oxidant is air, oxygen-rich air, oxygen-depleted air, or combinations thereof;

injecting at least a portion of a compressed recycle stream by means of a combustion temperature control system into the combustion chamber, thereby generating a discharge stream to be expanded in an expander that drives a main compressor and generates a gaseous exhaust stream having a water component and a gaseous component, wherein the compressed recycle stream moderates the temperature of the discharge stream, and wherein the compressed recycle stream is injected into the combustion chamber independent of the compressed oxidant;

increasing the pressure of the gaseous exhaust stream with a boost compressor and cooling the gaseous exhaust stream with one or more cooling units fluidly coupled to the boost compressor, whereby a cooled recycle gas comprising substantially all of the gaseous component of the gaseous exhaust stream that passes through the boost compressor is directed into the main compressor for compression, wherein the main compressor compresses the cooled recycle gas to generate the compressed recycle stream;

cooling a purge stream fluidly coupled to compressed recycle stream with a heat exchanger to generate a cooled purge stream;

directing the cooled purge stream into an absorber column having a potassium carbonate solvent circulating therein, the potassium carbonate solvent being configured to absorb CO₂ present in the cooled purge stream;

discharging a nitrogen-rich residual stream and a bicarbonate solvent solution from the absorber column;

flashing the bicarbonate solvent solution to a lower pressure through a first valve, thereby generating a reduced-pressure solution;

using a separator fluidly coupled to the first valve to remove a first portion of CO₂ from the reduced-pressure solution;

flashing a remaining portion of the reduced-pressure solution to a near-atmospheric pressure through a second valve, thereby generating a near-atmospheric bicarbonate solvent solution;

boiling the near-atmospheric bicarbonate solvent solution in a regeneration column to remove a CO₂ and water mixture therefrom, thereby generating a regenerated potassium carbonate solvent;

recirculating the regenerated potassium carbonate solvent back to the absorber column;

separating a second portion of CO₂ from the CO₂ and water mixture in a condenser fluidly coupled to the regeneration column, wherein the pressure of the first portion of CO₂ is higher than the pressure of the second portion of CO₂; and

separately directing the first portion and the second portion of CO₂ into a downstream compression system.

17. The method of claim 16, further comprising increasing the temperature of a portion of the regenerated potassium carbonate solvent in a reboiler to produce a heated regenerated potassium carbonate solvent.

18. The method of claim 17, further comprising recirculating the heated regenerated potassium carbonate solvent back into the regeneration column to produce steam for boiling the bicarbonate solvent solution.

19. The method of claim 16, further comprising directing the second portion of CO₂ to a first stage of the downstream compression system and directing the first portion of CO₂ to an intermediate stage of the downstream compression sysstem.

20. The method of claim 19, further comprising directing a portion of the water separated from the CO₂ and water mixture in the condenser back into the regeneration column to create steam.

21. The method of claim 16, further comprising withdrawing a portion of the bicarbonate solvent solution from the regeneration column prior to complete solvent regeneration, and feeding the withdrawn bicarbonate solvent solution low into the absorber column.

22. An integrated CO₂ separation system, comprising:

a gas turbine system having a combustion chamber configured to substantially stoichiometrically combust a compressed oxidant and a fuel, where the compressed oxidant is air, oxygen-rich air, oxygen-depleted air, or combinations thereof;

a combustion temperature control system to inject at least a portion of a compressed recycle stream into the combustion chamber to generate a discharge stream and to act as a diluent to control temperature of the discharge stream, wherein the compressed recycle stream is injected into the combustion chamber independently of the compressed oxidant;

an expander configured to expand the discharge stream to generate a gaseous exhaust stream and at least partially drive a main compressor;

an exhaust gas recirculation system having a boost compressor and one or more cooling units fluidly coupled to the boost compressor, the boost compressor being configured to receive and boost the pressure of the gaseous exhaust stream and the one or more cooling units being configured to cool the gaseous exhaust stream and provide a cooled recycle gas to the main compressor, wherein the main compressor receives the cooled recycle gas which comprises substantially all of a gaseous component of the gaseous exhaust stream that passes through the boost compressor and wherein the main compressor compresses the cooled recycle gas and generates the compressed recycle stream;

a purge stream fluidly coupled to the compressed recycle stream and having a heat exchanger configured to reduce the temperature of the purge stream and generate a cooled purge stream and low pressure steam; and

a CO₂ separator fluidly coupled to the heat exchanger, the CO₂ separator comprising;

an absorber column configured to receive the cooled purge stream and circulate a potassium carbonate solvent therein to absorb CO₂ in the cooled purge stream, wherein the absorber column discharges a nitrogen-rich residual stream and a bicarbonate solvent solution;

a first valve fluidly coupled to the absorber column and configured to flash the bicarbonate solvent solution to a lower pressure, thereby generating a reduced-pressure solution;

a separator fluidly coupled to the first valve and configured to receive the reduced-pressure solution and remove a first portion of CO₂ therefrom;

a second valve fluidly coupled to the separator and configured to receive a remaining portion of the reduced-pressure solution and flash the remaining portion to a near-atmospheric pressure, thereby generating a near-atmostpheric bicarbonate solvent solution;

a regeneration column fluidly coupled to the second valve and configured to receive and boil the near-atmospheric bicarbonate solvent solution to remove a CO₂ and water mixture therefrom, thereby producing a regenerated potassium carbonate solvent;

one or more mixing chambers fluidly coupled to the regeneration column and corresponding one or more eductors, the one or more mixing chambers being configured to receive the regenerated potassium carbonate solvent, and the one or more eductors being configured to receive the low pressure steam from the heat exchanger and flash-boil the regenerated potassium carbonate solvent to extract a second portion of CO₂ and water to be recirculated back to the regeneration column;

a pump fluidly coupled to at least one of the one or more mixing chambers and configured to direct a remaining portion of regenerated potassium carbonate solvent back to the absorber column; and

a condenser fluidly coupled to the regeneration column and configured to receive and separate a second portion of CO₂ from the CO₂ and water mixture removed from the near-atmospheric bicarbonate solvent solution;

wherein the pressure of the first portion of CO₂ is higher than the pressure of the second portion of CO₂ and the first portion and the second portion of CO₂ are separately directed to a downstream compression system.

23. The system of claim 22, wherein the second portion of CO₂ is directed to a first stage of the downstream compression system and the first portion of CO₂ is directed to an intermediate stage of the downstream compression system.

24. The system of claim 23, wherein a first portion of the water separated from the CO₂ and water mixture is pumped back into the regeneration column to create steam.

25. The system of claim 24, wherein a second portion of the water separated from the CO₂ and water mixture is directed to the heat exchanger to generate the low pressure steam.

26. The system of claim 22, further comprising a reboiler fluidly coupled to the regeneration column and configured to receive and heat a portion of the regenerated potassium carbonate solvent and produce a heated regenerated potassium carbonate solvent to be recirculated back into the regeneration column to produce steam for boiling the bicarbonate solvent solution.

27. A method of separating CO₂ , comprising:

substantially stoichiometrically combusting a compressed oxidant and a fuel in a combustion chamber, where the compressed oxidant is air, oxygen-rich air, oxygen-depleted air, or combinations thereof;

injecting at least a portion of a compressed recycle stream by means of a combustion temperature control system into the combustion chamber, thereby generating a discharge stream to be expanded in an expander that drives a main compressor and generates a gaseous exhaust stream, wherein the compressed recycle stream moderates the temperature of the discharge stream, and wherein the compressed recycle stream is injected into the combustion chamber independent of the compressed oxidant;

increasing the pressure of the gaseous exhaust stream with a boost compressor and cooling the gaseous exhaust stream with one or more cooling units fluidly coupled to the boost compressor, whereby a cooled recycle gas comprises substantially all of a gaseous component of the gaseous exhaust stream that passes through the boost compressor is directed into the main compressor for compression, wherein the main compressor compresses the cooled recycle gas to generate the compressed recycle stream;

using at least one oxygen sensor disposed on one of an outlet or an inlet of the expander or on an outlet of the combustion chamber and operatively connected to a flow control system to determine a preferred amount of the oxidant to be injected into the combustion chamber by the flow control system;

cooling a purge stream fluidly coupled to compressed recycle stream with a heat exchanger to generate a cooled purge stream and a low pressure steam;

directing the cooled purge stream into an absorber column having a potassium carbonate solvent circulating therein, the potassium carbonate solvent being configured to absorb CO₂ present in the cooled purge stream;

discharging a nitrogen-rich residual stream and a bicarbonate solvent solution from the absorber column;

flashing the bicarbonate solvent solution to a lower pressure through a first valve, thereby generating a reduced-pressure solution;

removing a first portion of CO₂ from the reduced-pressure solution with a separator fluidly coupled to the first valve;

flashing a remaining portion of the reduced-pressure solution to a near-atmospheric pressure through a second valve, thereby generating a near-atmospheric bircarbonate solvent solution;

boiling the near-atmosphoeric bicarbonate solvent solution in a regeneration column to remove a CO₂ and water mixture therefrom, thereby generating a regenerated potassium carbonate solvent;

separating a second portion of CO₂ from the CO₂ and water mixture in a condenser fluidly coupled to the regeneration column, wherein the pressure of the first portion of CO₂ is higher than the pressure of the second portion of CO₂ ;

separately injecting the first portion and the second portion of CO₂ into a downstream compression system;

injecting the low pressure steam into one or more eductors fluidly coupled to one or more mixing chambers, wherein the one or more mixing chambers are configured to receive the regenerated potassium carbonate solvent;

flash-boiling the regenerated potassium carbonate solvent from the regeneration column in one or more mixing chambers fluidly coupled to one or more eductors to produce an effluent comprising a third portion of CO₂ and water;

accelerating the low pressure steam through the one or more eductors to extract the effluent from the one or more mixing chambers, wherein the effluent is recirculated back to the regeneration column; and

recirculating a remaining portion of regenerated potassium carbonate solvent back to the absorber column.

28. The method of claim 27, further comprising directing the second portion of CO₂ to a first stage of the downstream compression system and directing the first portion of CO₂ to an intermediate stage of the downstream compression system.

29. The method of claim 28, further comprising directing a first portion of the water separated from the CO₂ and water mixture in the condenser back into the regeneration column to create steam.

30. The method of claim 29, further comprising directing a second portion of the water separated from the CO₂ and water mixture in the condenser to the heat exchanger to generate the low pressure steam.