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Articulo 3 Ciclos
Global warming potential and net power output analysis of natural gas
combined cycle power plants coupled with CO2 capture systems and
organic Rankine cycles
poles Rivera*
~ o, Fabricio Na
Gerardo Geovanni Esquivel Patin
s de Hidalgo, Morelia, Michoaca
Chemical Engineering Department, Universidad Michoacana de San Nicola n, 58060, Mexico
a r t i c l e i n f o a b s t r a c t
Article history: The objective of this study was to analyze the environmental and energetic analysis of a natural gas
Received 19 June 2018 combined cycle (NGCC) power plant integrated with post-combustion carbon capture (PCC) and an
Received in revised form organic Rankine cycle (ORC) as an alternative to increase net power output using thermal integration
8 October 2018
between the three processes. This study consisted of the calculation of the global warming potential
Accepted 9 October 2018
(GWP) and the net power output as a function of the amount of CO2 captured. For the analysis, the base
Available online 10 October 2018
was taken as the simulation of a 453-MWe NGCC power plant with a monoethanolamine-based PCC
process and an ORC. The base case shows that the ORC could generate a considerable amount of energy
Keywords:
ngcc power plant
using a stream of hot water to evaporate the working fluid; this stream was previously extracted from the
Post-combustion carbon capture low pressure turbine and used in the stripper reboiler. Then three study cases were considered. For case 1
Organic Rankine cycle (NGCC þ PCC þ ORC), the power output is 381.2 MW with a capture of 42.43 kg/s of CO2 and a production
Global warming potential of 2.02 MW in the ORC with a GWP of 94.75 g CO2e/kWh. For case 2, exhaust gas recirculation (EGR) was
considered. For this case, the energy production is 386.52 MW, with 1.905 MW produced in the ORC. For
case 3 with PCC and NGCC thermal integration, the net power output is 391.42 MW. These three cases
were analyzed and the amount of combustive gases were varied to determine the effect on the power
output, CO2 captured, and the GWP of these processes. The results show the tradeoffs between the
considered goals and set an objective framework for policymakers to better operate these types of
systems.
© 2018 Elsevier Ltd. All rights reserved.
1. Introduction Marquez et al., 2017), the rectisol process (Sharma et al., 2016),
calcium looping methods (Petrescu and Cormos, 2017), etc. have
The carbon capture process is a good alternative for reduction of been completed. Nevertheless, post-combustion carbon capture
greenhouse gas emissions in the chemical and processing in- (PCC) using chemical absorption that includes an absorber and a
dustries. This process has been studied for its application in all stripper in which gases from power plants are treated with lean
types of industries such as cement production (Cormos and solutions (Sreedhara et al., 2017) is among the most studied and
Cormos, 2017), iron and steel (Cormos, 2016), power plant mature technologies (Araújo and de Medeiros, 2017). Although
(Kanniche et al., 2010), etc. However, among the challenges in different types of absorbents have been analyzed, the energetic
applying this technology is the energetic and economic impact penalty of CO2 capture (including the energy used in the amine
which in the case of a power plant results from matching both regeneration process, pumps, vents and compression train) re-
technologies. Several capture technologies such as pre-, oxy-, and mains a considerable issue affecting the electricity cost. The ener-
post-combustion and the analysis of different materials for capture getic impact for the PCC could be reduced using exhaust gas
as membranes (Khalilpour et al., 2015), ionic liquids (Valencia- recirculation (EGR), which increases the CO2 concentration during
the absorption process and decreases the required energy (Li et al.,
2011). Despite these efforts, natural gas combined cycle (NGCC)
plant efficiency remains low in comparison to the stand-alone
* Corresponding author.
~ o), fnapoles@
plant.
E-mail addresses: espagio_91@hotmail.com (G.G. Esquivel Patin
umich.mx (F. N
apoles Rivera). The thermodynamic and economic analysis of an NGCC power
https://doi.org/10.1016/j.jclepro.2018.10.098
0959-6526/© 2018 Elsevier Ltd. All rights reserved.
12 G.G. Esquivel Patin poles Rivera / Journal of Cleaner Production 208 (2019) 11e18
~ o, F. Na
plant with PCC has been studied to improve the plant efficiencies 2. Methodology
(Hu et al., 2017). For example, thermal integration using the energy
in the streams of the capture process in the heat recovery steam To create a basis for comparison the following simulations were
generator (HRSG) and in the stripper reboiler might increase the conducted:
net power output from 0.77 to 1.31% (Luo et al., 2015). ORC
implementation has been studied to reduce energy penalties a) A 453-MW NGCC, PCC MEA-based process and an ORC with
resulting from carbon capture (Romeo et al., 2011). In this study, an R245FA as a working fluid with a fixed amount of combustion
ORC (consisting of a conventional Rankine cycle using R245fa as the gases.
working instead of water) was considered; this process uses the b) A 453-MW NGCC, PCC MEA-based process, exhaust gas recir-
waste energy of the process to generate additional power (Schuster culation (EGR) and an ORC with R245FA as a working fluid with
et al., 2009). a fixed amount of combustion gases.
It is known that power generation from fossil fuels results in a
considerable emission of greenhouse gases and that CO2 is the gas Then, an analysis of the GWP and power output for the base
emitted in a higher proportion to the environment (IPCC, 2014). For cases was performed and used to assess the performance of the
an NGCC power plant, the CO2 emissions are approximately system in terms of the GWP and power output under the following
190e600 kg/MW for an NGCC with a generation capacity of scenarios:
approximately 390e1600 MWe (Martín-Gamboa et al., 2018), a
considerable amount that has to be reduced. The CO2 could be used - Case 1: PCC þ NGCC þ ORC and a varying amount of combustion
during other processes or stored; for example, it has been proposed gases during the capture process
to use the CO2 during the methanol production process (Milani - Case 2: PCC þ NGCC þ ORC with EGR and a varying amount of
et al., 2015). combustion gases during the capture process
The match of an NGCC power plant with PCC and ORC has been - Case 3 PCC þ NGCC þ ORC with EGR and PCC-NGCC thermal
previously studied (Esquivel-Patin ~ o et al., 2017). However, the integration and varying amount of combustion gases during the
simulation parameters and the amount of CO2 captured were fixed. capture process
In this study, the match between the three technologies was
analyzed considering the addition of the monoethanolamine (MEA)
production process. A life-cycle analysis for the integrated process 3. ASPEN PLUS® simulation for the base case
was performed and a sensitivity analysis for the simulation pa-
rameters was conducted to optimize the operational conditions. The three processes were simulated in ASPEN PLUS® to
Then a sensitivity analysis for the combustion gases sent to the construct the base case and models, and results from Luo et al.
capture process was completed to determine the relationship be- (2015), Ozdil and Segmen (2016), and the IEAGHG report (2012)
tween this variable and the simulation parameters. The simulation were used for the validation and comparison of the simulation
of the base case was conducted for a 453-MWe NGCC power plant results. The simulation was separated into four sections, one for
with a 35 wt% MEA-based PCC process and an ORC with R245fa as each thermodynamic model: Peng-Robinson with Boston Mathias
the working fluid. The global warming potential (GWP) was modifications (PR-BM) for the gas turbine of the NGCC, STEAMNBS
calculated with the IPCC values (2017) relative to the CO2 for the for the steam turbines, ELECTNRTL for the PCC, and SRK for the ORC.
NGCC, natural gas production, and MEA production. The flow chart in Fig. 1 shows all the streams and equipment for the
HP-TURB
HP-STEAM
AIR-COMP MP-TURB
AIR MP-STEAM
LP-TURB
COM-CHAM
LP-STEAM
GAS-TURB
MIX-GAS
GAS-PCC
GAS-HRSG
MIXER
Condenser
NAT-GAS HRSG
WATER
EGR
CO2-CT
GAS-TREA
CO2
L-AMINE
COMP-1 STR
COMP-2
ABS
ORC-TURB
R-AMINE
PURGE
S-1
ORC-COND MEA
R245FA STEAM-LP
NGCC that consists of a gas turbine and three pressure level steam Fig. 2 shows a schematic representation of the problem. The
turbines; the PCC with a 35 wt% MEA-based absorber using the calculation of the power output for the base case is the sum of the
kinetic data of Zhang et al. (2009); a stripper and a compression gas turbine, steam turbine, and ORC turbine considering a reduc-
system; and an ORC with a condenser, evaporator, and turbine. As a tion in the final power output because of the energy used for
result of the match between the NGCC and PCC it was observed that operation of the plant, the steam extracted to regenerate the L-
the stream of the LP steam used in the stripper reboiler has an amine, and the energy used in the compression train. The GWP
output temperature of 120.8 C (stream S-1 in Fig. 1) and it has to be calculation involves three stages: the impact resulting from the
cooled to recirculate it in the Rankine cycle to the heat recovery natural gas production (NGP), the emission in the NGCC process
steam generator (HRSG). In the IEAGHG report the stream is cooled production, and finally the MEA production (MEAP) which was
with the stream of gases sent to the environment from the included as part of the life cycle analysis to obtain a more complete
absorber. In this case, the stream is used as waste energy that can be GWP result. For emission in the NGP, it was considered that 1.4% of
used to operate the ORC to generate more power and increase the the natural gas feed to the NGCC was emitted to the environment
thermal efficiency of the NGCC. (Harrison et al., 1997); the amount of natural gas was 16.62 kg/s
Using this simulation, the obtained power output was with a composition of methane of 84%. As a result, the emissions in
379.2 MW with a capture of 42.43 kg/s and a stripper reboiler duty the NGP plant was constant and equal to 31,404 kg CO2e/h which
of 186.782 MW, which are near the values reported by Lue et al. was used in the GWP calculation for that stage in the global process
(379.85 MW, 41.11 kg/s and the 186.8 MW). The power output for which varies depending on the net power output obtained in each
the ORC was 0.2602 MW in comparison to the 0.2604 MW of Ozdil case. For the MEAP stage, only the CO2 emission according to the
and Segmen. data obtained in Ecoinvent (2017) were considered; the impact of
this stage varied according to the necessary MEA and the power
output in each case study. Finally, for emissions in the NGCC in the
4. Analysis of the base case
base case the emissions are at the exit of the absorber. For the three
stages, the Intergovernmental Panel on Climate Change (IPCC)
Once the simulation results are consistent with the results of the
values in CO2-e grams used for GWP calculation were 21 for CH4,
authors previously cited, the analysis of the base case was con-
310 for N2O, and 1 for CO2. For the MEAP GWP, it was considered
ducted considering three scenarios for the evaluation of the net
that 1.2% of the initial flux of the MEA has to be fed to regenerate the
power output and GWP: first for the match of the NGCC, PCC and
lean solvent. Thus, for the GWP calculation, an approximate
ORC; second for the same match but with an EGR; and finally the
quantity that includes the sum of the initial feed of the MEA as well
NGCC, PCC, and ORC with EGR and thermal integration (TI) per-
as the MEA needed over 1 year were used to regenerate the lean
formed using SYNHEAT (Yee and Grossmann, 1990).
GWP
MEA production
Compression train
CO2
GWP
GWP
GWP
NGCC Power Plant MEA
Natural Gas
Combustion
Gases
R-Amine
L-Amine
Water to
HRSG
LP STEAM
Hot water
ORC
solvent, and divided over 8000 h of operation. main variables of the process such as power output in the ST and
The results of the three scenarios for the base case show that for ORCT, LP steam extracted, stripper reboiler duty, carbon capture,
case 1 (NGCC þ PCC þ ORC) the power output is 381.2 MW with a GWP impact of the stages considered, GWP global, and net power
capture of 42.43 kg/s of CO2 and a production of 2.02 MW in the output. First, as can be seen in Fig. 5, a separation unit in the PCC
ORC with a GWP of 94.75 g CO2e/kWh. In case 2, it the EGR is was used to guarantee that the combustion gases sent to the PCC
386.52 MW with 1.905 MW produced in the ORC and a GWP of and the stream of the lean amine simultaneously varied to maintain
92.27 g CO2e/kWh. For case 3, with the TI, it 391.42 MW were a desirable ratio of LCO2/GAS-PCC To achieve this, the split fraction
produced with 1.73 MW produced in the ORC and a GWP of 91.11 g in the separation unit for the stream GAS-PCC was specified.
CO2e/kWh For each case the number of stages was fixed at 8. All the As a result of the base case, it was observed that the combined
results of the base case are shown in Table 1. A shown in Fig. 3 the flux of the stream of the lean amine and the combustion gases is
net power output in each turbine during the process included the 42.0021 kmol/s for case 1 and 30.681 for case 2. This is because the
gas turbine (GT) which has a diminution of 0.12% in the case with EGR decreases the flux of the combustion gases sent to the PCC but
the EGR compared to the first case and for the steam turbines (STs) with nearly the same amount of CO2 because of the increment in
initially there is a reduction of 33.9% when the PCC is coupled. the CO2 concentration. The number of stages for the absorber was
Finally, when EGR and TI are used, it was observed that as the 10 and for the stripper 8 for both cases. Then, a sensitivity analysis
necessary LP steam to desorb the CO2 decreases the power output varying the combined flux and the number of stages from 2 to 15
of the ST increases. The power output of the organic Rankine cycle was completed. The results of the first analysis show that for a
turbine (ORCT) is 2.02 MWe and it depends on the amount of hot constant LCO2/GAS-PCC ratio the composition of the streams of
water at the output of the stripper reboiler; as the LP steam in the combustion gases and of the lean amine are constant It was also
PCC decreases, the ORCT power output decreases as well. observed that the simulation is infeasible when the number of
The GWP contribution for each stage of the process is shown in stages is less than 6, and that the quantity of CO2 does not
Fig. 4. It can be seen that the GWP changed under all the scenarios considerably change when the number of stages varies from 6 to 15.
with respect to the base case. Initially, there is a reduction in the Then, as a result of the first analysis, the stages of the absorber were
GWP resulting from the implementation of the PCC and ORC that fixed at 10 and the number of stages in the stripper varied from 2 to
reduces the CO2 emissions in the NGCC; the GWP change is 15 to observe the behavior of the stripper and the effect in the duty
considerably higher in comparison to the GWP increment associ- of its reboiler and in carbon capture. For less than five stages, the
ated with the addition of the MEAP process. Then, in the case of CO2 capture is negligible, and the reboiler duty considerably in-
EGR, the GWP decreases because of the reduction in the stripper creases for five stages compared that for 6 to 15 stages. For both
reboiler duty and with this an increase in the power output of the analyses, it was observed that the minimum combined flux of the
LP turbine. Finally, in the last case, the diminution in GWP is caused lean amine and combustion gases is 12 kmol/s to achieve feasible
by the TI between the streams in the compression train that pre- solutions.
heat the stream of the stripper reboiler, decreasing the amount of Finally, using the previous results, a new sensitivity analysis for
LP steam and obtaining a higher net power output. Because of the the three study cases was performed varying the GAS-MEA stream
modification previously mentioned, the impact of the GWP during and the stripper number of stages (5e10), taking as the response
the NGCC stage is reduced to between 3.47 and 3.53% for the three variables the CO2 capture and the stripper reboiler duty. Once these
scenarios compared to the stand-alone plant. This GWP of the NGP results were obtained, the flux of MEA, carbon emitted to the
stage increases because the net power output is reduced while the environment; carbon captured; reboiler duty and compression
natural gas consumption is the same. The MEAP stage has a lower power in the PCC; LP steam that has to be extracted; LP turbine
impact in comparison to that of the other stages because the power output; ORCT power output; and GWP of the MEAP, NEP, and
quantity of MEA feed to regenerate the lean-amine stream is just NGCC for the three study cases can be evaluated.
2140.08 kg/h which corresponds to 0.086 CO2 kg/s emitted to the
environment according to the calculation performed using the data 6. Results
of kg-CO2/kg-MEA reported by ECOINVENT.
From the simulations, it was found that the maximum amount
5. Analysis of GWP and power output varying the amount of of CO2 capture for case 1 was 43.45 kg/s. but this also led to the
combustion gases for case 1 of PCC þ NGCC þ ORC, case 2 of maximum reboiler duty required of 211.89 MW using 15 stages in
PCC þ NGCC þ ORC with EGR and case 3 of PCC þ NGCC þ ORC the stripper, and extraction of 86.64 kg/s of LP steam affecting the
with EGR and PCC-NGCC TI net power output to obtain just 373.53 MWe, which compared with
the stand alone plant, corresponded to a diminution of 17.2%. This is
The main objective of this analysis was to determine the effect of a considerable quantity compared to the diminution in the base
varying the amount of combustion gases sent to the PCC in the case of 15.45% with a capture of 42.43 kg. Because of this, the results
Table 1
Results of the analysis in the base case.
Result NGCC þ PCC þ ORC NGCC PCC þ ORC þ EGR NGCC PCC þ ORC þ EGR þ TI
450
400
350
300
250
200
150
100
50
0
NGCC + PCC NGCC + PCC NGCC + PCC +
NGCC
+ORC +ORC + EGR ORC + EGR + TI
ORCT 0 2.02 1.905 1.73
ST 171.5 113.38 116.69 121.74
GT 295.12 295.12 294.75 294.75
Fig. 3. Power generated in each turbine of the process (MWe) and for the study cases.
400
350
300
250
200
150
100
50
0
NGCC + PCC NGCC + PCC NGCC + PCC +
NGCC
+ORC +ORC + EGR ORC + EGR + TI
MEAP 0 2.77 2.77 2.73
NGCC 348.654 9.6 8.35 8.15
NGP 69.52 82.38 81.25 80.23
Fig. 4. GWP contribution (g CO2e/kWh) for each stage of the process and for the study cases.
of the base case were taken as the upper bound. For the minimum 6.1. Case 1
GAS-MEA combined flux for the first case, it was observed that the
minimum amount of CO2 that could be captured was between 11.29 The results for varying the Gas-MEA flux are shown in Fig. 6. The
and 11.49 kg/s depending on the number of stages in the stripper. number of stages was taken as 6 for a flux of 12e24, 7 for 24e36,
With this level of capture, the net power output had a penalty of and 8 for 36e42 kmol/s because of the analysis in the changes in
3.6e4.9% compared to the case when no CO2 is captured. For case 2, the stripper reboiler duty and in the capture level in kg/s. The
the minimum capture was 14.93e15.21 kg/s This increment in maximum CO2 was the same of the base case with 42.43 kg/s with a
comparison to that of case 1 was because of the increase in con- minimum of 11.35 kg/s for the 6 stages in the stripper. The energetic
centration of the CO2 in the absorber caused by the EGR. and environmental results shown in Fig. 6 are as follows: stripper
16 G.G. Esquivel Patin poles Rivera / Journal of Cleaner Production 208 (2019) 11e18
~ o, F. Na
CO2-E CO2-T
L-CO2 CO2
GAS-PCC R-CO2
L-MEA
250
200
150
100
50
0
12 21 30 39 42
STRQ (MW) 55.32 94.65 134.76 172.88 186.78
CTP (MW) 4.02 6.95 9.88 12.67 13.58
SE (kg/s) 22.62 38.7 55.1 70.69 76.38
STP (MW) 154.4 142.12 129.61 117.72 113.38
ORCP (MW) 0.5982 1.024 1.457 1.87 2.02
GWP MEAP (g CO2e/kWh) 0.7011 1.271 1.883 2.539 2.77
GWP NGP (g CO2e/kWh) 72.97 75.57 78.398 81.29 82.38
GWP NGCC (g CO2e/kWh) 271.05 191.94 116.8 39.29 9.6
CC (kg/s) 11.35 21.59 30.75 39.53 42.43
reboiler duty (STRQ), necessary power in the compression train MEA flux, the level of capture for the three central points in case 1
(CTP), LP steam extracted (SE), steam turbine power output (STP), remained constant for comparison to this case. In addition, the
ORC power output (ORCP), GWP potential contribution during the number of stages was the same for each point as in case 1. For case
MEA production stage (GWP MEAP), GWP potential contribution 2, the maximum CO2 was the same as that of the base case of
during the NGP stage (GWP NGP), GWP potential contribution in 41.205 kg/s with a minimum of 15.06 kg/s. The results of Case 2
the natural gas combined cycle stage (GWP NGCC), and level of showed a similar trend as those of case 1 including the following
carbon captured (CC). observations:
As can be seen in Fig. 6 if the combustion gases sent to the
absorber decrease, the LP turbine power increases because the LP The maximum level of capture for this case is less than that of
steam extracted is reduced as is the contribution of the GWP during case 1, which is compensated for by the stripper reboiler duty
the NGCC stage as a result of more CO2 emissions. The GWP in the decrease.
MEAP and in the NGP decrease because the net power output in- The minimum level of capture is greater compared to that of
creases from the maximum point to the minimum caused by the case 1 because the CO2 concentration is higher because of the
diminution of the stripper reboiler duty, which has an effect on the EGR.
LP steam, LP power output, and ORC power output. The LP steam was reduced approximately 2e5% in the compa-
rable points owing to the EGR.
6.2. Case 2 The GWP of each stage is nearly the same in the two cases
because of the small changes in the net power output and in the
As the combined flux Gas-MEA changes in the second case lean amine fed in the absorber.
because of the EGR of the results shown in Fig. 7 by varying the Gas-
G.G. Esquivel Patin poles Rivera / Journal of Cleaner Production 208 (2019) 11e18
~ o, F. Na 17
250
200
150
100
50
0
12 16.262 22.705 29.372 30.681
STRQ (MW) 70.657 95.159 131.864 169.373 176.18
CTP (MW) 5.266 7.084 9.858 12.648 13.185
SE (kg/s) 28.892 38.91 53.919 69.257 72.041
STP (MW) 149.61 141.966 130.513 118.811 116.686
ORC2 (MW) 0.7641 1.029 1.426 1.832 1.905
GWP MEAP (g CO2e/kWh) 0.9814 1.358 1.961 2.63 2.77
GWP NGP (g CO2e/kWh) 73.679 75.3 77.89 80.71 81.25
GWP NGCC (g CO2e/kWh) 244.19 193.13 117.98 41.1 8.25
CC (kg/s) 15.06 21.59 30.75 39.53 41.205
Acknowledgements
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