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

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

Part 1
1.	Acknowledgements				xi
2.	Notation				xii
3.	Abstract				1
4.	Summary				1
S.1	Overview of Energy Cycle				3
S.2	Mining, Preparation, and Transportation of Raw Materials				5
S.3	Handling of Coal and Limestone				6
S.4	Base Case for Integrated Gasification Combined Cycle				6
S.5	Integrated Gasification Combined Cycle with CO₂ Recovery				7
S.6	Pipeline Transport of CO₂				9
S.7	Sequestering of CO₂				10
S.8	Comparison of Power and CO₂ Emissions for IGCC/Shift/CO₂ Recovery System				11
S.9	Economics of CO₂ Recovery, Transport, and Sequestering				13
	S.9.1	Direct Costs for IGCC/Shift/CO₂ Recovery			13
	S.9.2	Direct Costs for Pipeline			14
	S.9.3	Costs of Replacement Electricity			14
	S.9.4	Summation of Capital, Operating, and Replacement Electricity Costs			15
S.10	References for Summary				16
1.0	Introduction				17
	1.1	Background			17
	1.2	Goals, Objectives, and Approach			17
2.	Mining				20
	2.1	Extraction			20
		2.1.1	Deep Mining		21
		2.1.2	Coal-Cleaning Circuit		22
	2.2	Rail Transport			23
	2.3	Impact of Plant Location on CO₂ Budget			23
	2.4	Economics			24
	2.5	Limestone Mining			24
	2.6	Limestone Rail Transport			25
3.	Kellogg-Rust-Westinghouse IGCC: Coal and Limestone Preparation				26
4.	Kellogg-Rust-Westinghouse IGCC: Gasifier				26
	4.1	Overview			27
		4.1.1	Description of the Gasifier		27
		4.1.2	Shift Reaction		28
		4.1.3	Recovery Process		29
	4.2	Shift Reaction			31
	4.3	Heat Recovery and Process Integration			38
5.	Integrated Gasification Combined Cycle with Amine CO₂ Recovery				44
	5.1	Feed Gas Preparation and Process Integration			44
	5.2	Carbon Dioxide Recovery by Amines			45
	5.3	Power System Performance Effects of the MEA Process			53
	5.4	Major Equipment Specification and Preliminary Cost Estimation			53
		5.4.1		Heat Exchanger before First-Stage Shift Reactor	53
		5.4.2		Heat Exchanger between First and Second Shift Reactors	54
		5.4.3		Heat Exchanger after Second-Stage Shift Reactor	63
		5.4.4		First-Stage Shift Reactor	64
		5.4.5		Second-Stage Shift Reactor	64
		5.4.6		Cost of Catalyst	64
		5.4.7		Absorption Tower	64
		5.4.8		Stripping Column	64
		5.4.9		Lean Solvent Cooler	64
		5.4.10		Interstage Cooler for Absorber	64
		5.4.11		Lean-Rich MEA Heat Exchanger	65
		5.4.12		Stripper Overhead Condenser	65
		5.4.13		Stripper Reboiler	65
		5.4.14		Solvent Circulation Pump	65
		5.4.15		Carbon Dioxide Product Gas Compressors	66
Part 2
6.	Integrated Gasification Combined Cycle with Glycol Solvent CO₂ Recovery				67
	6.1	Feed Gas Preparation and Process Integration			67
	6.2	Carbon Dioxide Recovery by a Glycol Solvent			67
	6.3	Power System Performance Effects of the Glycol Solvent Process			72
	6.4	Major Equipment Specification and Preliminary Cost Estimation			72
		6.4.1		High-Pressure Glycol Solvent Case	72
		6.4.2		Low-Pressure Glycol Solvent Case	97
7.	Integrated Gasification Combined Cycle with Chilled Methanol CO₂Recovery				109
	7.1	Feed Gas Preparation and Process Integration			109
	7.2	Carbon Dioxide Recovery by Chilled Methanol			109
	7.3	Power System Performance Effects of the Chilled Methanol Process			120
	7.4	Major Equipment Specification and Preliminary Cost Estimation			121
		7.4.1		Heat Exchanger before First-Stage Shift Reactor	121
		7.4.2		Heat Exchanger between First and Second Shift Reactor	121
		7.4.3		Heat Exchanger after Second-Stage Shift Reactor	121
		7.4.4		Heat Exchanger for Raw Gas Cooling	130
		7.4.5		First-Stage Shift Reactor	130
		7.4.6		Second-Stage Shift Reactor	130
		7.4.7		Cost of Catalyst	130
		7.4.8		Absorption Tower	130
		7.4.9		Stripping Column	131
		7.4.10		Flash Tank 1	131
		7.4.11		Recycle Gas Compression	131
		7.4.12		Flash Tank 2	131
		7.4.13		Flash Tank 3	131
		7.4.14		Flash Gas Compressor 1	132
		7.4.15		Flash Gas Compressor 2	132
		7.4.16		Solvent Circulation Pump	132
		7.4.17		Lean-Rich Methanol Heat Exchanger	132
		7.4.18		Carbon Dioxide product Gas Compressors	132
		7.4.19		Solvent Refrigeration	132
8.	Integrated Gasification Combined Cycle with Hot Potassium Carbonate CO₂ Recovery				133
	8.1	Feed Gas Preparation and Process Integration			133
	8.2	Carbon Dioxide Recovery by Hot Potassium Carbonate			134
	8.3	Power System Performance Effects of the Hot Potassium Carbonate Process			142
	8.4	Major Equipment Specification and Preliminary Cost Estimation			142
		8.4.1		Heat Exchanger before First-Stage Shift Reactor	142
		8.4.2		Heat Exchanger Between First and Second Stage Shift Reactor	142
		8.4.3		Heat Exchanger After Second-Stage Shift Reactor	147
		8.4.4		First-Stage Shift Reactor	148
		8.4.5		Second-Stage Shift Reactor	148
		8.4.6		Cost of Catalyst	148
		8.4.7		Absorption Tower	148
		8.4.8		Stripping Column	148
		8.4.9		Lean Solvent Cooler	149
		8.4.10		Stripper Overhead Condenser	149
		8.4.11		Solvent Circulation Pump	149
		8.4.12		Carbon Dioxide Product Gas Compressors	149
9.	Integrated Gasification Combined Cycle with Calcium Oxide CO2 Recovery				150
	9.1	Background			150
	9.2	Sorbents			150
	9.3	Optimum Conditions for Reaction			151
	9.4	Carbon Dioxide Capture: Carbonation			151
	9.5	Carbon Dioxide Release: Calcination			151
	9.6	Macroscale Physical Propertied of the Sorbent, Support Geometry, and Bed Depth			152
	9.7	Louisiana State University Carbonation as a Shift Reactor			152
	9.8	Process Performance with Trace Gases			152
10.	Integrated Gasification Combined Cycle with Low-Temperature Polymer Membrane CO2 Recovery				153
	10.1	Gas Pretreatment and Operating Conditions			153
	10.2	Polymer Membrane Selectivity			153
	10.3	Membrane Separation: Conclusions			154
11.	Transport of CO₂ by Pipeline				155
	11.1	Commercial Considerations of CO₂ Separation Systems for Pipeline Gas			155
	11.2	Supercritical Compression for CO2 Pipeline			156
	11.3	Substation Recompression			158
	11.4	Total Power Consumption for CO₂ Pipeline			159
	11.5	Costs for CO₂ Pipeline: Compression and Dehydration			159
	11.6	Commercial Pipelines			163
12.	Sequestering of CO₂				165
	12.1	Overview of Geologic Processes: The Dominance of Ocean Sequestering			165
	12.2	Terrestrial Biological Sequestering			167
	12.3	Ocean Sequestering			168
	12.4	Geologic Sequestering: Aquifers			168
	12.5	Geologic Sequestering: Depleted Oil and Gas Reservoirs			169
		12.5.1		Natural Gas Outflow Calculations	169
		12.5.2		Inflow Calculations	173
	12.6	Conclusions			176
13.	Conclusions				177
	13.1	Summary of Energy Consumption and CO₂Emissions			177
		13.1.1		Base-Case IGCC	177
		13.1.2		IGCC/Shift/Amine CO₂ Recovery Case	177
		13.1.3		IGCC/Shift/Glycol CO₂ Recovery Case	177
		13.1.4		IGCC/Shift/Methanol CO₂ Recovery Case	178
		13.1.5		IGCC/Shift/Carbonate CO₂ Recovery Case	182
	13.2	Summary of Economics			182
		13.2.1		Direct Costs for IGCC/Shift/CO2 Recovery	182
		13.2.2		Direct Costs for Pipeline	186
		13.2.3		Costs for Replacement Electricity	189
		13.2.4		Summation of Capital, Operating, and Replacement-Electricity Costs	195
14.	References				196