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Energy 267 (2023) 126634

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Energy
journal homepage: www.elsevier.com/locate/energy

A new process splitting analytical method for the coal-based Allam cycle:
Thermodynamic assessment and process integration
Tuantuan Xin a, Cheng Xu a, *, Yongping Yang a, Vladimir Kindra b, Andrey Rogalev b
a
Key Laboratory of Power Station Energy Transfer Conversion and System of Ministry of Education, North China Electric Power University, Beijing, 102206, China
b
Department of Innovative Technologies of High-Tech Industries, National Research University “Moscow Power Engineering Institute”, Moscow, 111250, Russia

A R T I C L E I N F O A B S T R A C T

Handling Editor: L Luo Coal-based Allam cycle, an efficient oxy-fuel combustion semi-closed supercritical carbon dioxide (sCO2) cycle
coupled to coal gasification, can realize the zero carbon emission to the atmosphere. The aim of this study is to
Keywords: develop a new process splitting analytical method to clearly illustrate the energy conversion performance of the
Allam cycle complex system and guide the process integration for efficiency improvement. Based on the new analytical
Coal gasification
method, the basic coal-based Allam cycle is split into four parts, including a closed sCO2 cycle, a closed steam
Efficiency improvement
Rankine cycle, open process and air separation unit (ASU). Then, the process splitting analytical models are
Process integration
Process splitting constructed and the process integration is carried out in three aspects: the heat integration of ASU, the steam
Thermodynamic analysis extraction for pre-drying and gasification, and the integration of sCO2 cycle for heat recovery of raw syngas.
Finally, the net efficiency of the modified coal-based Allam cycle is improved to 42.48% using the new process
splitting analytical method, which is 3.68% points higher than that of the basic configuration. The developed
process splitting analytical method might give a new perspective to evaluate the energy conversion performance
of the complex coal-based semi-closed power cycle in a clear and simple way.

1. Introduction • For oxy-fuel combustion, the fuel is combusted with high-purity


oxygen and the component of the flue gas is nearly pure CO2,
Coal plays a vital role in electricity generation worldwide. Coal-fired which can be directly captured and stored after cooling process.
power plants currently fuel 37% of global electricity and will still
generate 22% of the world’s electricity in 2040 [1]. However, burning CCS technologies above can limit carbon emissions from coal-fired
coal releases a large amount of carbon dioxide (CO2) to the environment power plants, but also decreases the net efficiency with the energy
of above 0.7–1 kg_CO2/kWh [2]. CO2 is called a greenhouse gas because penalty for CO2 separation and compression [6]. To reduce energy
it traps heat in the atmosphere [3]. To reduce the CO2 emission, 80% of consumption, the carbon capture technologies can be improved by
coal use is expected to be equipped with Carbon Capture and Storage development of new absorbents with lower heat requirement and opti­
(CCS) by 2050, according to the International Energy Agency (IEA) [4]. mization of operation parameters and processes. Sharifzadeh et al. [7]
There are three major technological routes used for CO2 capture [5], compared a new amine-promoted buffer salt solvent and the conven­
termed as post-combustion, pre-combustion, and oxy-fuel combustion. tional monoethanolamine baseline solvent for CO2 capture and the re­
sults showed that the net efficiency of the pulverized coal power plant
• Post-combustion capture is usually applied to the conventional pul­ with CCS using the new solvent is 1.3 %-points higher. Garlapalli et al.
verized coal-fired plants, which scrubs the flue gas exhausted from [8] integrated a novel heat recovery unit with the CCS in coal fired
the boiler by chemical solvents. power plants, which recovered thermal energy contained in flue gas to
• Pre-combustion capture should be integrated with the gasification, lower reboiler heat duty by 31.2%, and the net conversion efficiency of
using a shifted reactor to convert steam (H2O) and CO to H2 (fuel) power plant could increase by 0.5 %-points compared to basic case.
and CO2 (that is captured by chemical solvents). Wang et al. [9] proposed a new CO2 capture system driven by double
absorption heat transformer to upgrade low-temperature steam into a
higher level to match the temperature of CO2 regeneration. For the

* Corresponding author.
E-mail address: xucheng@ncepu.edu.cn (C. Xu).

https://doi.org/10.1016/j.energy.2023.126634
Received 11 August 2022; Received in revised form 30 November 2022; Accepted 5 January 2023
Available online 7 January 2023
0360-5442/© 2023 Elsevier Ltd. All rights reserved.
T. Xin et al. Energy 267 (2023) 126634

pre-combustion capture in the coal fueled power plant integrated with integration of ASU and optimization of the CO2 turbine. Xin et al. [24]
gasification, in addition to the adoption of the new absorbents and also integrated the Allam cycle with the coal-to-methanol process to
process/parameter optimization, the energy penalty can be reduced by recover the unreacted syngas for power generation with nearly zero
improving the CO shift process. Gazzani et al. [10] applied the sorption emission, and the net power output of the novel system is 29.4% greater
enhanced water gas shift, which could combine CO2 conversion and than the conventional system integrated with the combined cycle and
removal, to the pre-combustion capture process, and the net electric pre-combustion carbon capture.
efficiency was calculated as 36.3%–37.7% with the 90%–98% CO2 Aforementioned investigations demonstrated that the Allam cycle
captured. For the oxy-fuel combustion capture, the energy consumption used for coal fueled power generation has the potential to realize both
for CO2 separation is pretty low due to the high concentration in the flue the zero emission and high energy conversion efficiency. Moreover, the
gas but the required high-purity oxygen for combustion, produced by air thermodynamic performance of the coal-based Allam cycle can be
separation unit (ASU), has to consume a great amount of energy [11]. further improved by process integration, e.g. heat integration of ASU
The development of the CCS technologies can effectively reduce the and efficient recovery of the heat released by the raw syngas cooling.
energy consumption for carbon capture but the efficiency of the power Although some studies have been conducted to show the efficiency en­
plant with CCS is usually lower than the current power plants without hancements of the modified coal-based Allam cycle by simulation of the
CCS by 7–11 %-points. overall system, the energy saving mechanism is still unclear and thus it is
To offset the energy penalty for CCS, the power plant can adopt the hard to carry out the process integration in a simple and clear way, e.g.
higher efficiency thermodynamic cycle, e.g., supercritical CO2 (sCO2) why integration of the ASU with recuperation process can improve the
cycle, in which the sCO2 is used as the working fluid for power gener­ net power efficiency? Is the heat recovered from the raw syngas cooling
ation [12]. The sCO2 cycle features the advantages of both Bryton cycle used for steam generation or integrated with the sCO2 cycle? Is the
and Rankine cycle [13]: (1) the phase is gas during recuperation process required steam for pre-drying and gasification of coal from the heat
to reduce the exergy destruction; and (2) the power consumption of recovery of raw syngas or the extraction of the steam turbine? In pre­
compression is low due to the small compressibility factor near the vious studies [25,26], we have proposed a general simple method for
critical point. The sCO2 cycle can be applied to the power plants driven evaluate the process modification of thermal cycles, named as thermal
by concentrated solar energy, nuclear fission as well as fossil fuel, e.g., cycle splitting analytical method, which can visually illustrate the
coal. Mecheri et al. [14] investigated the sCO2 cycles applied to coal effectiveness of different modification measures by the constructed
power plant and found that the novel plant theoretically offered satis­ “equivalent power cycle”. Sun et al. [27] also proposed an analytical
factory thermodynamic performance with the 47.8% efficiency based on constituent split method to analyze a semi-closed sCO2 cycle, which
lower heating value (LHV). Sun et al. [15] proposed the overlap ab­ equivalently splits the semi-closed cycle into an open cycle of fuel and
sorption of flue gas energy for the sCO2 coal fired power plant, using oxidant and a closed sCO2 cycle for deepening the understanding of the
bottom cycle to absorb a part of high temperature flue gas heat, which cycle. If the process splitting analytical idea is applied to the coal-based
can effectively improve the energy conversion efficiency of the overall Allam cycle, the superior thermodynamic performance can be clarified
system. Liu et al. [16] compared the performance of coal fired power and the benefit of the process integration can also be revealed by the
plants integrated with sCO2 cycle and steam Rankine cycle, and found constructed splitting analytical models, which might help to guide the
that the decrease in heat transfer irreversibility in the boilers mainly process integration of the coal-based Allam cycle for efficiency
caused the efficiency enhancements of 2.52%–2.84%. To reduce the improvement.
carbon footprints, the coal fired sCO2 cycle should adopt the CCS tech­ Against the backdrop, a thorough process splitting analysis is con­
nologies. Olumayegun et al. [17] evaluated the thermodynamic per­ ducted for the coal-based Allam cycle to illustrate the energy conversion
formance of sCO2 cycles for coal fired power generation with solvent performance and thermodynamic benefit of the process integration in a
based CO2 capture. Results showed that the net efficiency of the sCO2 simple and clear way. In this study, the coal-based Allam cycle is first
cycle plant was 0.68–1.31% higher than the supercritical steam cycle split into several energy conversion processes, regarding the oxy-fuel
with CCS but the plant net efficiency is still relatively low of 31.13%– combustion, closed thermal cycles, heat recovery of the raw syngas
31.76% based on higher heating value (HHV). cooling and air compression in ASU. Then, the process splitting
Among various CCS technologies, today there is an increasing in­ analytical models are constructed to evaluate the energy conversion of
terest in the oxy-combustion semi-closed power cycles, which use these processes. Finally, the split processes are coordinately combined to
recycled CO2 and/or H2O as working fluid instead of air and realize improve the net efficiency of the overall power generation system.
nearly zero carbon emission to the atmosphere [18]. Allam cycle, pro­
posed by R.J. Allam et al. [19], is an oxy-combustion semi-closed sCO2 2. Process splitting of the coal-based allam cycle
cycle, which employs sCO2 as working fluid and can reach a competitive
efficiency compared with the best current systems without CO2 capture. 2.1. Coal-based Allam cycle and process integration
Due to the superior performance, this advanced zero-emission cycle has
attracted a great deal of attention amongst the communities for research For the coal-based Allam cycle electric power generation system, the
and development of the fossil-fueled power generation. Scaccabarozzi coal is gasified into syngas and then the gaseous fuel is combusted with
et al. [20] confirmed the outstanding performance of the pure oxygen to drive a semi-closed sCO2 power cycle. In this study, the
natural-gas-fired Allam cycle with the maximum efficiency of 54.8% by LURGI pressure gasifier [28] is adopted, which uses the steam and ox­
a thorough thermodynamic analysis and optimization. For the ygen as the gasifying agents, and the oxygen for both gasification and
coal-based Allam cycle, the coal should be converted to syngas by combustion is produced by the cryogenic ASU, in which the air is
gasification. Weiland et al. [21] make a techno-economic analysis of an compressed and then condensed to liquid to separate the oxygen by the
integrated gasification coal-fired Allam cycle and the plant thermal ef­ distillation columns [29]. Fig. 1 (a) shows the basic configuration
ficiency can reach 40.6% including CCS, which is superior to the con­ layout, including the gasification, heat recovery and Allam cycle power
ventional integrated gasification combined cycle using the same gasifier. generation subsystems. Firstly, the pre-dried coal is fed to the gasifier to
Luo et al. [22] investigated the exergy performance of the coal-fired react with steam and oxygen for syngas production. Then, the raw
Allam cycle, and declared that there is some potential for improving syngas is cooled down and cleaned up to remove water and sulphur. The
the overall efficiency by integrating the ASU with the remaining system. heat released by the raw syngas cooling is recovered to generate steam
Zhao et al. [23] conducted the simultaneous optimization and heat for pre-drying, gasification as well as power generation by driving a
integration of the Allam cycle coupled to coal gasification process and steam turbine. In the Allam cycle, the compressed syngas is combusted
the net efficiency can be increase from 39.29% to 41.41% by heat with the high-purity oxygen and the sCO2 as working fluid is also fed to

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T. Xin et al. Energy 267 (2023) 126634

Fig. 1. Basic configuration of the coal-based Allam cycle (a) and process integration (b).

the combustor to moderate the combustion temperature. The hot com­ the thermodynamic performance of the coal-based Allam cycle, the
bustion flue gas, mainly consisting of CO2 and H2O, expands through the process splitting analytical method is developed to split the complex
gas turbine to generate shaft power, which is converted to electricity as system into several simple thermal cycles and equivalent heat-to-
the final product by the generator. Most of the thermal energy within the thermal processes, which might separate the contribution of each sec­
exhaust flue gas is recuperated to heat the recycle sCO2. The flue gas out tion to the overall performance of the plant and clarify how a change
of the recuperator is further cooled down to the ambient temperature may affect them to guide the process integration for efficiency
and the water generated by the H2 combustion is removed by the improvement.
gas-liquid separator. The remaining of high-purity CO2 is compressed to
the supercritical pressure, of which most is recycled as working fluid to 2.2. Process splitting analytical method for the coal-based Allam cycle
finish the power cycle and the rest generated by CO combustion is
separated for carbon capture. The semi-closed cycle can be split into a closed cycle and an open
The thermodynamic performance of the overall system can be process [27]. For the oxy-fuel combustion power generation coupled to
further improved by process integration. As shown in Fig. 1 (b), there are coal gasification, the oxygen production and heat recovery of the hot
three process integration measures investigated: heat integration of the raw syngas should also be considered. As shown in Fig. 2, the coal-based
ASU with the recuperation, steam extraction for pre-drying and gasifi­ Allam cycle is split into four processes: a closed sCO2 cycle driven by
cation, and integration of the sCO2 cycle for heat recovery. The coal- syngas combustion, a closed steam Rankine cycle for heat recovery of
based Allam cycle is a complex power generation system, including the raw syngas cooling, open process (related to the coal gasification,
various energy transfer and conversion processes. To clearly illustrate syngas cooling, oxy-fuel combustion and electric power generation and

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Fig. 2. Process splitting of the energy conversion in the basic coal-based Allam cycle power generation system (a) and modified system (b).

consumption of the fuel, oxygen and combustion products), and oxygen modification measures for efficiency improvement, with the unchanged
production process. As a result, the net efficiency can be expressed as boundary parameters. However, this method cannot be used to optimize
following: the parameters of the overall system. For the parameter optimization,
( ) the complete system simulation should be adopted, which has not been
QsCO2 ⋅ηsCO2 + Wopen + Qsteam ⋅ηsteam − WASU
ηnet = (1) involved in this study.
mrc ⋅HHVrc

where mrc and HHVrc represent the mass flow rate and higher heating
2.3. Process splitting models
value of the raw coal feedstock, respectively; QsCO2 and ηsCO2 are the
heat input and efficiency of the closed sCO2 cycle, respectively; Qsteam
2.3.1. Process splitting of the semi-closed sCO2 cycle
and ηsteam are the heat input and efficiency of the steam Rankine cycle,
As shown in Fig. 3, the semi-closed sCO2 cycle is split into two parts:
respectively; WASU stands for the electric power consumption by the
the closed sCO2 cycle and the open process. The open process is related
ASU; and Wopen is the net power generated by the open process.
to the fuel combustion, including coal milling, syngas compression,
Based on the new analytical method, the energy conversion perfor­
oxygen compression, compression and pumping of the CO2 generated by
mance of the coal-based Allam cycle can be illustrated by the split
fuel oxy-combustion, and power generation by the combustion flue gas
processes in a clear and simple way. For the basic concept (Fig. 2a), the
expanding through the gas turbine. The heat input of the closed sCO2
oxy-fuel combustion heat is used to drive the sCO2 cycle; the heat
comes from the open process, including the oxy-combustion heat, Q1,
released from the syngas cooling is used to drive the steam Rankine
and the heat released by the exhaust combustion flue gas cooling, Q2,
cycle; additionally, the steam used for coal pre-drying and gasification is
which are calculated by the following expressions:
also supplied by the heat recovery of the syngas. For the modified
( )
concept with intensive process integration (Fig. 2b), the air compression Q1 = mCO2 ⋅ hc,1 − hc,5 (2)
heat of the ASU is recovered to drive the sCO2 cycle; the steam used for
[( ) ( )]
coal pre-drying and gasification is the steam extraction from the steam Q2 = mCO2 ⋅ hc,5 − hc,4 − hc,2 − hc,3 (3)
Rankine cycle to save more syngas cooling heat to drive the steam
Rankine cycle; and a portion of the syngas cooling heat can also be used where mCO2 is the mass flow rate of the CO2 recycled as working fluid; h
for the sCO2 cycle by heating the clean compressed syngas and recycle represents the specific enthalpy; and subscript c,i is the state point of the
sCO2 stream. recycled CO2.
In addition, it should be noted that the proposed method is mainly For the closed thermal power cycle, the ratio of the net power output
used to evaluate the thermodynamic performance of the coal-based to the heat input is defined as the cycle efficiency. As the boundary
Allam cycle and the contribution of the process integration parameters are determined, the cycle efficiency is expected to be a
constant value that the net power output (or net power output change) is

Fig. 3. Process splitting of the Allam cycle.

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directly proportional to the heat input (heat input change). To obtain the ( ) ( )/
efficiency of the closed sCO2 cycle, an additional heat, ΔQ, is introduced hs,1 − hs,2 ⋅ηm ⋅ηg − hs,4 − hs,3 (ηm ⋅ηmo )
ηsteam = ( ) (6)
to the closed sCO2 cycle by heating the recycled CO2, and the net power hs,1 − hs,4
output will increase linearly, which is validated in Section 4.1 (c.f. ( ) ( )/
Fig. 6). Therefore, the efficiency of the closed sCO2 cycle is obtained as hs,5 − hs,2 ⋅ηm ⋅ηg − hs,6 − hs,3 (ηm ⋅ηmo )
ηextraction = ( ) (7)
following: hs,5 − hs,6
Wnet ΔWnet
ηsCO2 = = (4) where ηg is the efficiency of the electric generator, and the subscript s,i
Q ΔQ
stands for state point of the steam (or water).

2.3.2. Equivalent thermal-to-power efficiency of the intercooling 2.3.4. Open process


compression in the ASU For the open process, the electric power consumption of the
As shown in Fig. 4 (a), an ASU primarily involves air compression, compressor (or pump) can be computed as following:
heat exchanger, cold production and distillation column. The energy ( )
consumption is the compression of air, which drives the refrigeration mcom ⋅ hiscom,out − hcom,in
cycle to produce cold for cryogenic separation of air. Conventionally, the Wcom = (8)
ηis,com ⋅ηm ⋅ηmo
air is compressed by the multi-stage compressor with intercooling to
reduce the power consumption. However, the heat released from the air
where mcom is the mass flow rate of the fluid for compression (or
intercooling cannot be recovered due to the low temperature of
pumping); hcom,in is the specific enthalpies of the stream at the inlet of
61.3–72.4 ◦ C. If the air is adiabatically compressed, the power con­
the compressor (or pump); hiscom,out is the theoretical specific enthalpy of
sumption would increase but the temperature of the compressed air can
the outlet stream through isentropic process; and ηis,com is defined as the
reach to 238.5 ◦ C and the heat released by the air cooling can be
isentropic efficiencies of compressor (or pump).
recovered, e.g., heating the recycle sCO2 in the recuperation process. In
The electricity consumption of the coal milling is related to the mass
other words, for the intercooling compression, the benefit is the less
flow rate of the coal input, which is calculated as:
power consumption and the cost is no heat recovered. As shown in Fig. 4
(b), the equivalent heat-to-power efficiency of the air intercooling Wmill = k⋅mcoal (9)
compression process can be calculated as following:
( )/ ∑ where k is the specific power consumption of coal powder.
ha,1 − ha,2 (ηm ⋅ηmo ) − w
ηintercooling = ( ) (5)
ha,1 − ha,3 3. Conditions and assumptions

where ηm is mechanic efficiency; ηmo represents the efficiency of the In this study, Zhundong coal, a typical Chinese low-rank coal, is
electromotor; Σw is the specific electric power consumption of the air selected as the feedstock with the mass flow rate of 100 kg/s. The overall
intercooling compression; and the subscript a,i stands for the state point system performance can be obtained by simulation of three subsystems,
of the air. including the coal gasification, heat recovery and acid gas removal, and
the Allam cycle.
2.3.3. Equivalent thermal-to-power efficiency of the extracted steam In the coal gasification unit, the dryer first pre-dries the raw coal
The heat released from the syngas cooling is recovered to generate from 26.4% moisture content to 9.72% (70% moisture is assumed to be
the steam at different pressure for coal pre-drying, gasification and removed by steam drying [30]), and the heat source is the steam
power generation by driving the steam Rankine cycle. In addition to the generated by the heat recovery of the hot raw syngas; the mill pulverizes
heat recovery of hot raw syngas, the steam for coal pre-drying and the pre-dried coal powder with the specific power consumption of 15
gasification can also be the extraction of the steam Rankin cycle. Based kWh/ton_coal [31]; and the temperature and pressure of the gasification
on the thermal cycle splitting analytical method (Fig. 5) [25], the effi­ is assumed as 1350 ◦ C [32] and 6.5 MPa [28], respectively, with
ciencies of the steam Rankine cycle and extracted steam can be steam/coal mass ratio of 0.25 to completely convert the coal to syngas.
expressed as following: In the heat recovery unit, the heat released from the raw syngas
cooling to generated the steam at the pressure of 9 MPa, 6.5 MPa and 3

Fig. 4. Configuration of the cryogenic ASU (a) and equivalent heat-to-power conversion (b).

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Fig. 5. T-s diagram of the steam Rankine cycle (a) and the equivalent power cycle to evaluate the thermal-to-power conversion of the extracted steam (b).

coupled to coal gasification. The detailed boundary parameters and


Aspen plus blocks for simulation of the coal-based Allam cycle are listed
in Table 1.

Table 1
Details of the conditions and assumptions of the coal-based Allam cycle [35].
Item Aspen block Condition and assumption

Coal gasification
Dryer Dryer Raw coal consists of 54.38% Carbon,
2.35% Hydrogen, 10.55% Oxygen,
0.47% Nitrogen, 0.41% Sulphur,
5.44% Ash and 26.4% Moisture with
the higher heating value of 20,519 kJ/
kg on receiver basis. 70% moisture is
removed by the dryer driven by the
steam of 240 ◦ C and 3.0 MPa.
Gasifier RStoic, RGibbs Temperature and pressure are 1350 ◦ C
and 6.5 MPa, respectively. Steam/coal
mass ratio is 0.25. RStoic block is used
to decompose the nonconventional
Fig. 6. Relation between the heat input from outside and net power output of
solid into constituent elements and the
the Allam cycle.
components of the raw syngas is
obtained by the RGibbs block.
MPa, which are used to drive the steam turbine for power generation, as Heat recovery and cleaning up
Steam generator and HeatX, Compr Turbine isentropic efficiency is
the agent for gasification, as the heat source for pre-drying, respectively.
steam Rankine (turbine model), assumed as 89%; pump efficiency is
In acid gas removal unit, only the sulfides (H2S and COS) are removed by cycle Pump 85%; pressures of the steam are 9 MPa,
the dry gas cleaning process, which absorbs sulfides into the activated 6.5 MPa, 3 MPa for Rankine cycle,
cokes [33]. gasification and pre-drying.
In the Allam cycle, the pressure and temperature of the live sCO2 is Acid gas removal Sep 99% of sulfides are removed.
Allam cycle
assumed as 1150 ◦ C and 30 MPa, respectively, and the turbine pressure
Combustor RGibbs Temperature and pressure are 1150 ◦ C
ratio is set to be 10 [19]. The turbine cooling is simulated by the and 30 MPa, respectively. Pressure
improved continuous model suitable for the working fluid of sCO2 drop ratio is 1%.
developed by Scaccabarozzi et al. [20]. The recuperator is a multi-flow CO2 turbine Compr (turbine Pressure ratio is 10. Turbine efficiency
model), Valve, is 0.89. Efficiency of electric generator
heat exchanger and the temperature difference of the cold-end is
Mix is 0.99. Temperature of coolant is
assumed as 10 ◦ C. The exhaust CO2 is pressurized to the supercritical 200 ◦ C.
state of 8 MPa by the four-stage compressor with intercooling and then Compressor and Compr, Pump, Temperature of working fluid at the
pumped to the maximum pressure. The ASU produces oxygen for both pump Heater cooler outlet is 25 ◦ C with the ambient
the coal gasification and syngas combustion with the specific electric temperature assumed as 15 ◦ C. The
isentropic efficiency of all the
power consumption of 245 kWh/ton_O2 [29].
compressors and pumps is set to be
The equipment units with the overall system is simulated by the 0.85. Electromotor efficiency is
commercial software Aspen Plus [34] and the accuracies for simulation assumed as 0.94.
of the gasification process and Allam cycle have been validated in our Recuperator MHeatX Temperature difference of the cold end
is 10 ◦ C. Pressure drop ratio is 0.5%.
previous studies [24,35] that components of the gasified syngas have
ASU Compr, Heater, Oxygen purity is 99.5%. Isentropic
− 3.10%–3.82% deviations compared with the experimental data; the MHeatX, Valve, efficiency of the main air compressor
simulated value of the net efficiency of the Allam cycle has − 0.11% Sep is 85% and the pressure of the
deviation compared with open literature on the same boundary pa­ compressed air is set to be 0.6 MPa in
rameters, proving the Aspen Plus can be used for the system level accordance to the specific electric
power consumption of 245 kWh/
investigation of the thermodynamic performance of the Allam cycle
ton_O2.

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4. Results and discussion Table 3


Thermodynamic performance of the coal-based Allam cycle.
4.1. Process splitting analysis of the basic case Item Unit Value Item Unit Value

Raw input MW 2051.9 CO2 turbine MW 1243.1


As shown in Table 2, the detailed parameters of each stream of the Syngas produced MW 1775.5 Steam turbine MW 61.6
coal-based Allam cycle are obtained by the process simulation in Aspen Heat recovered MW 300.7 Mill MW − 4.4
Plus, in regard to temperature (t, ◦ C), pressure (p, MPa), mass flow rate for turbine MW 166.9 ASU MW − 135.8
(m, kg/s) and specific enthalpy (h, kJ/kg). Table 3 shows the overall for gasifier MW 66.9 Compressor and pump MW − 368.4
for dryer MW 66.9 Net power output MW 796.1
system performance: (1) 2051.9 MW (on HHV basis) of raw coal is Net efficiency % 38.80
converted to 1775.5 MW syngas (on HHV basis) by gasification; (2)
166.9 MW heat recovered from the hot syngas is converted to 61.6 MW
electric power by the steam turbine, and the rest is recovered to generate
Table 4
steam for coal gasification and pre-drying; (3) the CO2 turbine driven by
Heat input of the sCO2 cycle and steam Rankine cycle.
the syngas-oxy combustion generates 1243.1 MW electric power; (4) the
auxiliary power consumptions are 4.4, 135.8, 368.4 MW for mill, ASU, Item t (◦ C) h (kJ/kg) m (kg/ Q (MW)
s)
and compression and pumping, respectively; (5) finally, the net power
output is 769.1 MW and the net efficiency is calculated as 38.80% on sCO2 Brayton cycle
Recuperator
HHV basis.
Hot side (input/ 728.2/60.2 − 8111.2/-8865.7 2462.6 − 1858.1
The above analysis can obtain the thermodynamic performance of output)
the overall system. Nevertheless, the energy conversion mechanism is Cold side (input/ 50.2/664.8 − 9090.5/-8192.6 2264.2 2032.9
still unclear for the complex system with coal gasification, oxy- output)
combustion, sCO2 cycle and steam Rankine cycle for heat recovery. Coolant (input/ 50.2/200 − 9090.5/-8812.1 198.4 55.2
output)
Therefore, the process splitting analytical models constructed in Section Combustor (input/ 664.8/ − 8192.6/-7555.7 2264.2 1442.9
2 is applied to the coal-based Allam cycle to clearly evaluate the energy output) 1150.0
conversion performance by the closed thermal power cycles and Steam Rankine cycle
equivalent heat-to-power processes. Water/Steam (input/ 15.5/550.0 − 15 897.4/-12 48.55 166.9
output) 459.0
The coal-based Allam cycle is split into the closed sCO2 cycle, closed
steam Rankine cycle, open process and ASU. Firstly, the efficiency of the
sCO2 cycle should be determined (c.f. Eq. (4)). Between the recuperator can be calculated as 1442.9 MW. In the recuperator, the heat required by
and combustor, a heater is added to heat the recycled sCO2 to introduce the cold streams of recycle sCO2 (2264.2 kg/s from 50.2 to 664.8 ◦ C) and
the additional heat input. As the additional heat input increases from the coolant (198.4 kg/s from 50.2 to 200 ◦ C) is 2088.1 MW (2032.9 +
zero to 1000 MW (Fig. 6), the net power output is linearly improved by 55.2 MW); while, the heat recuperated from the hot stream at the mass
526.8 MW. Therefore, the thermal efficiency of the closed sCO2 cycle flow rate of 2462.6 kg/s is 1858.1 MW as the temperature decreasing
can be easily obtained as 52.68%. from 728.2 to 60.2 ◦ C; hence, the heat input of the recuperator is 230.0
The heat input of the sCO2 cycle can be calculated by the enthalpy MW from the exhaust combustion flue gas. Based on the heat input
increment of the working fluid. As shown in Table 4, the heat input of (1442.9 + 230.0 MW) and cycle efficiency (52.68%), the net electric
the sCO2 cycle is from two positions, i.e., combustor and recuperator. In power output of the closed sCO2 cycle can be calculated as 881.3 MW.
the combustor, the temperature of the recycle sCO2 at the mass flow rate The efficiency of steam Rankine cycle, used for heat recovery, can be
of 2264.2 kg/s is increased from 664.8 to 1150.0 ◦ C and the heat input directly calculated as 36.60% (c.f. Eq. (6)) and its heat input can also be
easily calculated as 166.9 MW by the enthalpy increment. The electric
power consumption of the ASU is calculated to be 135.8 MW as the mass
Table 2
flow rate of oxygen for gasification and combustion is 153.9 kg/s. For
Detailed parameters of each stream in the basic coal-based Allam cycle.
the open process, the net power output is a negative value of − 10.5 MW
Stream t (◦ C) p (MPa) m (kg/s) h (kJ/kg)
since the power output of 147.6 MW driven by the combustion flue gas is
C-1 15.0 0.1 100.0 − 4875.7 less than the electric power consumption of other auxiliaries, including
C-2 105.0 0.1 81.5 − 2229.1 4.4 MW for coal pulverization, 56.0 MW for syngas compression, 86.0
SG-1 1350.1 6.5 149.0 − 2870.4
MW for oxygen compression and 11.7 MW for CO2 (generated by CO
SG-2 707.1 6.5 149.0 − 3991.0
SG-3 431.4 6.5 149.0 − 4439.9 combustion) compression and pumping.
SG-4 147.2 6.5 149.0 − 4889.1 As listed in Table 5, the thermodynamic performance of the coal-
SG-5 24.8 6.2 137.9 − 4438.3 based Allam cycle can be clearly illustrated. Furthermore, the effi­
SG-6 271.0 30.5 137.9 − 4060.4
ciency of the overall cycle might be improved by process integration to
FG-1 1150.0 30.0 2503.2 − 7607.5
FG-2 728.2 3.0 2701.6 − 8165.4
replace the low efficiency cycle/process with the high efficiency cycle/
FG-3 60.2 3.0 2701.6 − 8956.6 process, which is discussed based on the constructed process splitting
CO2-1 25.0 3.0 2663.6 − 8902.4 analytical models in the following section.
CO2-2 25.0 12.0 201.0 − 9117.6
CO2-3 25.0 12.0 905.7 − 9117.6
CO2-4 50.2 30.5 1556.9 − 9090.5
CO2-5 664.8 30.3 1358.6 − 8192.6
CO2-6 200.0 30.4 198.4 − 8812.1 Table 5
AIR-1 15.0 0.1 0.0 − 10.4 Process splitting analytical results of the coal-based Allam cycle.
O2-1 15.0 0.1 153.9 − 9.5
Item Unit Value Item Unit Value
O2-2 144.0 6.5 52.9 101.9
O2-3 164.1 12.0 101.1 116.9 sCO2 cycle Steam cycle
O2-4 55.0 30.5 1006.8 − 8160.5 Heat input MW 1672.9 Heat input MW 166.9
O2-5 664.8 30.3 1006.8 − 7303.7 Combustor MW 1442.9 Efficiency % 36.60
S-1 550.0 9.0 48.6 − 12 459.0 Recuperator MW 230.0 Net output MW 61.1
S-2 498.0 6.5 20.0 − 12 558.5 Efficiency % 52.68 Open process MW − 10.5
S-3 240.0 3.0 24.3 − 13 146.4 Net output MW 881.3 ASU MW − 135.8

7
T. Xin et al. Energy 267 (2023) 126634

4.2. Process integration which expands through the steam turbine for power generation, and the
steam for gasification and pre-drying is extracted from the steam tur­
4.2.1. Integration of the ASU bine. The effectiveness of the steam extraction modification for effi­
As shown in Fig. 7, although 230.0 MW heat of the combustion flue ciency improvement can also be clearly illustrated by the process
gas has been integrated with the recuperator, the temperature approach splitting analytical method.
of the recuperation is in range of 10–74.3 ◦ C, meaning that there is a In the heat recovery process, there are three thermodynamic process
great amount of exergy destruction. The large temperature difference including the steam Rankine cycle at 9 MPa, steam extraction at pressure
results from the heat capacity of the high-pressure CO2 (30 MPa, cold of 6.5 MPa, steam extraction at pressure of 3.0 MPa. Using the process
stream) is much higher than the low-pressure (3 MPa, hot stream) at the splitting analytical models constructed in Section 2.3, the efficiency of
temperature of 50–250 ◦ C. In other words, the heat supplied from the the steam Rankine cycle is 36.60%, the efficiency of 6.5 MPa steam
hot side is less than that the requirement of the cold side. In the ASU, if extraction is 35.08%, the efficiency of the 3.0 MPa steam extraction is
the air is directly compressed to 0.6 MW by an adiabatic compressor, the 30.78%. By the steam extractions replacing the low-pressure steam
temperature of the compressed air can reach 238.5 ◦ C and the heat generation to save more heat to drive the main steam Rankine cycle, the
released from the air cooling can be used to heat the recycled sCO2 in the heat-to-power efficiencies are improved by 1.52 and 5.82 %-points,
recuperator to reduce the exergy destruction with smaller temperature respectively. Moreover, the heat recovered from the raw syngas is
difference. To be specific, as the compressed air is cooled down to increased by 51.88 MW because the improved mass flow rate of high-
60.2 ◦ C with the temperature difference of the cold-end of 10.0 ◦ C, the pressure steam can help to match the heat capacities between the hot
temperature difference of the pinch point (Δt1, Fig. 7a) decreases to and cold streams as shown in Fig. 9 (b). The performance improvement
6.9 ◦ C, the maximum temperature difference (Δt2, Fig. 7a) decreases to can also be easily obtained by the process splitting models. As shown in
38.9 ◦ C, and the hot-end temperature difference (Δt3, Fig. 7a) is reduced Fig. 10, the increment of the net power output is calculated as 23.88 MW
to 31.7 ◦ C. However, on the other hand, the electric power consumption due to the higher heat-to-power efficiencies (66.87 × 1.52% + 66.92 ×
of the adiabatic compression is greater than the intercooling compres­ 5.82%) and greater heat recovered (51.88 × 36.60%).
sion. Therefore, it is hard to directly evaluate the effectiveness of the
heat integration of ASU and the efficiency is conventionally obtained by 4.2.3. Integration of sCO2 cycle for heat recovery
re-simulation of the overall modified system. As the efficiency of the sCO2 cycle is higher than that of the steam
Based on the process splitting analysis (c.f. Eq. (5)), for the inter­ Rankine cycle, it might contribute to the efficiency improvement to
cooling compression, the benefit is the specific electric power con­ integrate the raw syngas heat recovery process with the sCO2 cycle.
sumption reduced from 245.4 to 205.4 kJ/kg_air; but the cost is that Therefore, the high-temperature raw syngas is used to heat the recycle
183.81 kJ/kg_air heat from the adiabatic compression is eliminated. As a sCO2 and compressed clean syngas to drive the sCO2 cycle; and the low-
result, the equivalent heat-to-power efficiency of the intercooling temperature is used to generate steam for steam Rankine cycle.
compression can be calculated as 21.75%. In the modified system, the Fig. 11 presents the temperature distribution in the heat recovery
compression heat is used to drive the sCO2 cycle at the efficiency of process: since a portion of recovered heat is used to heat the recycle sCO2
52.68% by integrating with the recuperation process. As shown in Fig. 8, and clean syngas, and the mass flow rate of the steam generated by heat
the mechanism of the heat integration of adiabatic compression can be recovery is reduced. Restricted by the pinch point, the amount of heat
explained as the heat-to-power conversion efficiency can be improved recovered decreases with the mass flow rate of the generated steam
by 30.93 %-points compared with the intercooling compression. More­ reducing. On one hand, the heat recovered for driving the sCO2 cycle can
over, the net power increment can be easily obtained as 37.58 MW by improve the heat-to-power efficiency; on the other hand, the less heat
the efficiency improvement (30.93%) and heat integrated (121.48 MW). recovery might reduce the electric power generation. The constructed
process splitting analytical method can be used to evaluate the influence
4.2.2. Steam extraction for gasification and pre-drying of the amount of the heat recovery for driving sCO2 cycle on the overall
For the basic case, as shown in Fig. 9 (a), the heat recovered from the system performance.
raw syngas cooling is used to generated steam at different pressures for The amount of heat recovery for sCO2 cycle can be adjusted by
power generation, gasification and pre-drying, respectively. The heat adjusting the mass flow rate of steam for heat recovery. Since the steam
recovery process can also be modified as shown in Fig. 9 (b), the raw required for pre-drying and gasification are 21.5 and 20.0 kg/s,
syngas cooling heat is totally used to generate the high-pressure steam, respectively, the minimum amount of steam is 41.5 kg/s; and the

Fig. 7. Temperature distribution (a) and heat transfer performance (b) of the recuperation process in the sCO2 cycle.

8
T. Xin et al. Energy 267 (2023) 126634

Fig. 8. The energy saving mechanism of the heat integration of the ASU with the recuperation based on process splitting analysis.

Fig. 9. Temperature distributions of the raw syngas and steam in the heat recovery process: basic case (a) and modification case (b).

Fig. 10. Replacement of heat-to-power conversion among steams at different pressures.

maximum amount of steam is 102.6 kg/s if the syngas cooling heat is 4.3. Validation of the process splitting analysis
totally used for steam generation. As shown in Fig. 12, with the mass
flow rate of the steam decreasing from 102.6 to 41.5 kg/s, the heat The thermodynamic performances of the modified cases above are
recovered for steam Rankine cycle is reduced by 210.0 MW (from 352.6 directly obtained by the constructed process splitting analytical models
to 142.6 MW); on the other hand, the heat recovered for sCO2 cycle is without re-simulation. To validate the accuracy of the proposed process
increased from zero to 172.6 MW. Since the efficiencies of the steam analytical method, the thermodynamic performance of the three modi­
Rankine cycle and sCO2 cycle are 36.60% and 52.68%, respectively, the fied cases are also re-simulated by the Aspen Plus, including the heat
net power output is increased by 14.1 MW, meaning that the heat integration of ASU (Case I), the steam extraction (Case II), and the
integration with sCO2 cycle in the heat recovery process can effectively integration sCO2 cycle for heat recovery (Case III). The comparison re­
improve the energy conversion efficiency of the overall system. sults are listed in Table 6 that the net power increments obtained by the
Finally, after adopting the three process integration measures (i.e., process splitting analysis are very close to the overall system simulation
the heat integration of ASU, the stream extraction for pre-drying and with the relative errors below 0.1%. It proves that the constructed
gasification, and the integration of sCO2 cycle for heat recovery), the net process splitting analytical models can not only clearly explain how the
power output of the modified system can increase by 75.54 MW and the process integration measures effect the energy conversion performance
net efficiency soars to 42.68%, which is 3.68 %-points higher than the but also directly obtain the efficiency improvement at a high accuracy.
basic case. In addition, the detailed simulated stream parameters of the best

9
T. Xin et al. Energy 267 (2023) 126634

Table 7
Detailed parameters of each stream in the basic coal-based Allam cycle.
Stream t (◦ C) p (MPa) m (kg/s) h (kJ/kg)

C-1 15.0 0.1 100.0 − 4875.7


C-2 105.0 0.1 81.5 − 2229.1
SG-1 1349.9 6.5 149.0 − 2870.6
SG-2 886.9 6.5 149.0 − 3687.0
SG-3 684.0 6.5 149.0 − 4029.3
SG-4 127.9 6.5 149.0 − 4986.3
SG-5 24.8 6.2 137.9 − 4438.3
SG-6 218.8 30.0 137.9 − 4144.2
SG-7 450.4 30.0 137.9 − 3775.3
FG-1 1150.0 30.0 2881.9 − 7600.7
FG-2 728.5 3.0 3109.8 − 8157.9
FG-3 60.2 3.0 3109.8 − 8943.8
CO2-1 25.0 3.0 3071.8 − 8902.4
CO2-2 25.0 12.0 201.0 − 9117.6
CO2-3 25.0 12.0 905.7 − 9117.6
CO2-4 50.2 30.5 1965.1 − 9090.5
CO2-5 687.5 30.5 1737.2 − 8163.3
CO2-6 450.9 30.0 137.9 − 3774.5
CO2-7 200.0 30.5 227.9 − 8812.0
Air-1 15.0 0.1 660.9 − 10.4
Fig. 11. Temperature distributions of the raw syngas, sCO2, clean syngas and Air-2 238.5 0.6 660.9 218.0
steam in the heat recovery process. Air-3 60.2 0.6 660.9 34.1
O2-1 15.0 0.1 101.1 − 9.5
O2-2 144.0 6.6 52.9 101.9
O2-3 164.1 12.0 101.1 116.9
O2-4 55.0 30.5 1006.8 − 8160.5
O2-5 687.5 30.5 1006.8 − 7274.9
S-1 550.0 9.0 41.5 − 12459.0
S-2 497.6 6.5 20.0 − 12559.4
S-3 384.8 3.0 21.5 − 12772.8

based Allam cycle. The semi-closed sCO2 cycle coupled to coal gasifi­
cation is split into four parts: the closed sCO2 cycle driven by oxy-
combustion, steam Rankine cycle driven by heat recovery of raw syn­
gas, open process related to fuel combustion, and ASU. The strength of
the used method is that it is able to separate the contribution of each
section to the overall performance of the plant and clarify how a change
may affect them. Compared to a conventional simulation approach, it is
possible to know if a modification may be useful by directly comparing
the respective effects (efficiencies and heat duties) without running the
simulation of the overall system and interpreting the results. Main
Fig. 12. Influence of the heat distribution on the power output of conclusions can be obtained as follows.
heat recovery. The thermodynamic performance of the basic system can be clearly
evaluated by the constructed process splitting analytical models: as the
raw coal feedstock is 100 kg/s (2051.9 MW on HHV basis) the efficiency
Table 6 of the closed sCO2 cycle is 52.68% with heat input of 1672.9 MW; the
Validation of the process splitting analytical results by comparing with the efficiency of the closed steam Rankine cycle is 36.60% with the heat
simulation. input of 166.9 MW; the open process consumes 10.5 MW electric power;
Item Unit Case I Case II Case III the ASU consumes 135.8 MW electric power. As a result, the net power
Results obtained by simulation output of the overall system is 796.1 MW with the net efficiency of
CO2 turbine MW 1322.36 1322.36 1435.08 38.8% (HHV basis).
Steam turbine MW 61.64 86.12 8.57 The efficient energy conversion mechanism of the modified cases
Compressor and pump MW − 383.72 − 384.35 − 405.37
with process integration can be clearly illustrated by the process split­
ASU MW − 162.18 − 162.18 − 162.18
Mill MW − 4.40 − 4.40 − 4.40 ting analytical method: the heat integration of the ASU is to increase the
Net power output MW 833.69 857.55 871.69 heat-to-power efficiency of the air compression heat by 30.93 %-points
Net efficiency % 40.63 41.79 42.48 by replacing the intercooling process with the sCO2 cycle; the steam
Increment of the net power output extraction for pre-drying and gasification can not only increase the ef­
Overall system simulation MW 37.57 61.42 75.57
ficiency of the heat recovery for power generation, but also recover more
Process splitting analysis MW 37.58 61.46 75.54
Error % 0.02 0.06 − 0.05 heat of 51.9 MW for power generation at the efficiency of 36.60%; and
the integration of the sCO2 cycle for heat recovery can also effectively
improve the net power output by further improving the heat-to-power
modified coal-based Allam cycle (Case III) are also listed in Table 7. efficiency of heat recovery. Finally, the net efficiency of the optimized
coal-based Allam cycle soars to 42.48% by adopting the three integra­
5. Conclusion tion measures.
Additionally, the process splitting analytical idea might also be
In this study, the process splitting analytical method is developed for suitable for the thermodynamic analysis and process integration of other
the thermodynamic assessment and process integration of the coal- complex energy conversion systems (e.g. natural gas fired Allam cycle)

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T. Xin et al. Energy 267 (2023) 126634

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