Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
  • F01K13/00—General layout or general methods of operation of complete plants
  • F01K13/02—Controlling, e.g. stopping or starting
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E20/00—Combustion technologies with mitigation potential
  • Y02E20/32—Direct CO2 mitigation

Definitions

• the invention relates to power plants with CO2 capture and compression as well as their operation during frequency response.
• CCS carbon capture and storage
• Capture is defined as a process in which CO2 is removed either from the flue gases after combustion of a carbon based fuel or the removal and processing of carbon before combustion. Regeneration of any absorbents, adsorbents or other means to remove CO2 of carbon from a flue gas or fuel gas flow is considered to be part of the capture process.
• CO2 capture there are several possible approaches to CO2 capture in power plants, e.g. in coal fired steam power plants, gas turbine or combined cycle power plants.
• the main technologies under discussion for CO2 capture are so called pre-combustion capture, oxyfiring, chemical looping and post-combustion capture.
• Pre-combustion carbon capture involves the removal of all or part of the carbon content of a fuel before burning it. For natural gas, this is typically done by reforming it with steam, followed by a shift reaction to produce CO2 and hydrogen. The CO2 can be captured and removed from the resulting gas mixture. The hydrogen can then be used to produce useful energy.
• the process is also known as synthesis gas or syngas approach. The same approach can be used for coal or any fossil fuel. First the fuel is gasified and then treated in the same way as natural gas. Applications of this approach in combination with IGCC (Integrated Gasification Combined Cycle) are foreseen.
• IGCC Integrated Gasification Combined Cycle
• Oxyfiring also known as oxyfuel firing or oxygen combustion
• Oxyfiring is a technology that burns coal or other fossil fuel in a mixture of oxygen and recirculated CO2 rather than air. It produces a flue gas of concentrated CO2 and steam. From this, CO2 can be separated simply by condensing the water vapor, which is the second product of the combustion reaction.
• Chemical looping involves the use of a metal oxide as an oxygen carrier, typically a metal oxide, which transfers oxygen from the combustion air to the fuel.
• a metal oxide typically a metal oxide
• Products from combustion are CO2, reduced metal oxide and steam. After condensation of the water vapor, the CO2 stream can be compressed for transportation and storage.
• the CCS technology currently considered closest to large-scale industrial application is post combustion capture combined with compression, transportation and storage.
• post-combustion capture the CO2 is removed from a flue gas. The remaining flue gas is released to the atmosphere and the CO2 is compressed for transportation and storage.
• There are several technologies known to remove CO2 from a flue gas such as absorption, adsorption, membrane separation, and cryogenic separation.
• the CO2 capture and the compression of CO2 for further processing, i.e. transport and storage are the main resons for a decrease in the net power output reduction of a plant relative to a conventional plant without CCS.
• the EP1688173 gives an example for a post combustion capture and a method for the reduction of power output penalties due to CO2 absorption, respectively the regeneration of the absorption liquid.
• the WO2007/073201 suggests to use the compression heat, which results from compressing the CO2 stream for regeneration of the absorbent.
• the EP0537593 describes a power plant that utilizes an absorbent for CO2 capture from the flue gases, where the regenerator is switched off during times of high power demand and where the CO2 capture continues by use of absorbent stored in an absorbent tank during these times.
• the EP0537593 describes a simple on/ off mode of one power consumer of the CO2 capture equipment. It adds only very little operational flexibility at relatively high cost.
• the EP0858153 describes the basic principles of frequency response, in which a grid has a grid frequency, which fluctuates around a nominal frequency.
• the power output of said power plant is controlled as a function of a control frequency, in such a matter that the power output is increased when the control frequency decreases below said nominal frequency, and in the other hand the power output is decreased when the control frequency increases beyond said nominal frequency.
• the grid frequency is continuously measured.
• the EP0858153 describes a favorable method to average the grid frequency and to use the measured grid frequency as the control frequency, however it is limited to the conventional control mechanisms of a gas turbine power output control. To enable response to under- frequency events, plant normally have to operate at part load.
• the main objective of the present invention is to optimize the frequency response operating method for power plants with CO2 capture and compression.
• a further object of the invention is a power plant with a CO2 capture and compression system designed to operate according to the optimized operating method.
• the power consumption of a CO2 capture system is used as a control parameter for the net power output of a power plant during an under- frequency event.
• the electrical power consumption mechanical power consumption as for example in direct CO2 compressor drives as well as consumption of live steam, which otherwise can be converted into electrical energy in a steam turbine, are considered as power consumption of the capture system.
• An under- frequency event which is often also called under- frequency excursion or low frequency event, is a reduction in a power grid's frequency below the nominal frequency.
• the frequency response capability of the plant is improved by using fast variations of CO2 capture and compression equipment power consumption to modify the electric power the plant can deliver to the power grid during an under- frequency event.
• the essence of the invention is a plant operating method, in which the power consumption of the CO2 capture system is reduced or the system is shut down to increase the net output of the plant as a reaction to a drop in the grid frequency.
• a CO2 capture system is defined as the entire CO2 capture unit plus the compression unit with all their auxiliaries.
• This operating method gives additional flexibility in addition to the existing control of the plant. Due to the integration of the CO2 system into the power plant with this method, the net output of the plant can be increased at a very high rate during an under- frequency event and no part load operation is required to assure net power capacity for frequency response. High rate power variations can be realized by fast gradients in the power consumption of the CO2 capture system. The plant can therefore operate with optimum efficiency at or close to base load. This invention is realized at no or very little additional cost.
• the net output of the plant can be increased in response to an under- frequency event by increasing the gross power output of a plant and by decreasing the auxiliary or parasitic power consumption of the plant and any of its systems.
• the increase in gross power output is limited to base load of the plant.
• the rate at which the gross power of a plant can be increased is limited due to thermal stresses, which occur during transients and inertia of the plant.
• the possibilities to decrease parasitic power consumption of any system or auxiliaries are also very limited.
• the biggest consumers for a steam or combined cycle power plant are the feed water pumps, cooling water pumps and cooling equipment, which cannot be switched off during continuous operation.
• the large power consumption of CO2 capture and compression which are not required for a safe continuous operation of the plant change the situation and give new possibilities for fast transient changes in net power without encountering limitations on the plant.
• the power consumption of the CO2 capture system can be used as a control parameter for the plant's net power output.
• the power consumption for CO2 capture and compression can be changed and this power can be used to meet the frequency response requirements of a power grid.
• lifetime consuming fast load transients of the plant in response to under- frequency events can be avoided or reduced with this new concept as changes in net power output are met by a control of the power consumption of the CO2 capture system.
• frequency response with CO2 capture and compression is the possibility to avoid derated operation of the plant, which might be required by the grid if no more capacity for frequency reserve is available.
• some plants might be required to operate at part load, for example 90% load in order to keep a power reserve for under- frequency events. Operation at 90% can lead to reduced efficiency and increases the capital and operational cost per MWh produced.
• the present invention allows a plant to operate at or close to base load with optimum efficiency and still have an inherent power reserve for under- frequency events as the power consumption of the CO2 capture system can be switched off and used for frequency response.
• the CO2 capture and CO2 compression equipment or its main power consumers can simply be switched off during an under- frequency event.
• the CO2 separation, independent of chosen technology, is stopped and the plant is running like a conventional plant with CO2 emissions in the flue gases.
• no CO2 compression with its parasitic power demand is required.
• Reduced capacity can be realized by operating at least one of the CO2 capture system's components below the capacity required to reach the nominal CO2 capture rate. As a consequence the capture rate will be reduced during frequency response.
• under- frequency events occur only very seldom and over a short period of time the accumulated amount of CO2 not captured due to this operation mode is typically small and can be neglected.
• under- frequency events which would lead to such a short term CO2 emission occur only once in several years and will only last for a few minutes or a couple of dozen minutes.
• the captured CO2 can for example be released via a bypass of the CO2 compression unit during an under- frequency event.
• the captured CO2 it can for example be mixed with the flue gases downstream of the CO2 absorption unit and released via the stack of the power plant.
• Regeneration typically is done by "re- boiling" of the absorbent, which means heating the absorbent by steam in order to release the CO2. In consequence the steam is no longer available for power production. Once the regeneration is stopped during frequency response operation, the steam is available for power production.
• a third option in which also the absorption process is stopped or operated at reduced capacity, leads to further reduction in auxiliary power consumption. This reduction in power consumption is significantly smaller than the savings achieved in the first two options.
• auxiliary power consumption is significantly smaller than the savings achieved in the first two options.
• shut down of CO2 capture system's components their part load operation is possible.
• the mass flow of the CO2 compression unit can be reduced by control means such as inlet guide vanes.
• the shut down of at least one compressor would obviously also lead to a reduction of the CO2 compression unit's power consumption.
• shut down of one compressor train would lead to a reduction in power consumption by 50% but also implicate that 50% of the captured CO2 cannot be compressed and would typically be bypassed to the stack.
• the resorption rate can be reduced. This can for example be realized by reducing the flow of absorbent through the regeneration unit and bypassing the remaining flow and mixing the two flows before they enter the absorbtion unit.
• Another possibility to operate the absorption unit without regeneration or regeneration at reduced capacity of absorbent during an under- frequency event is to use stored absorbent for CO2 during this time.
• Different control methods for operation of the CO2 capture system are possible.
• One example is an open loop control of the different components of the CO2 capture system. This is particularly suitable in the case that only on/ off control of the different components is used.
• Open loop control is also conceivable for a more sophisticated operating process in which a continuous control of the power consumption of the CO2 capture system, i.e. without sudden steps in the power output due to on / off switching of different components, is realized.
• continuous control of the power consumption of the CO2 capture system is realized by the variation of one component's power consumption at a time, while the remaining components operate at constant load.
• closed loop control can be advantageous for example for transient operation or operation under changing boundary conditions.
• a closed loop control will allow better optimization of the load distribution. This is especially advantageous if a control of the CO2 capture rate is implemented. In this case the power consumption of the CO2 capture system is not varied by the control of one single component at a time, while the remaining components operate at constant load. The reduction in capacity of the different components has to be coordinated. For this a feed back of the current operating conditions of each component is advantageous and a closed loop control is preferable.
• a further subject of this invention is a thermal power plant for the combustion of carbon-based fuels with a CO2 capture system, which is designed for operation according to the frequency response method described above.
• the corresponding CO2 capture system is enabling fast system deloading.
• a plant in accordance with the present invention typically includes, in addition to the conventional components known for power generation, a CO2 capture unit for removing CO2 from the flue gas stream, and a CO2 compression unit.
• the capture unit typically includes capture equipment, in which the CO2 is removed from the flue gas, a regeneration unit, in which the CO2 is released from the absorbent, adsorbent or other means to bind the CO2 from the flue gas, and a treatment system for conditioning the CO2 for transportation.
• the compression unit consists of at least one compressor for CO2 compression.
• the compression unit also consists of at least one cooler or heat exchanger for re- cooling compressed CO2 during and/or after the compression.
• a steam turbine of the plant is designed to convert the maximum steam flow into energy, which can be produced by the plant with the CO2 capture system switched off.
• the generator and electrical systems are designed to convert the maximum power, which is produced with the CO2 capture system off, into electrical power and to transmit this electric power to the grid.
• the CO2 compressor can safely vent the CO2, and for example leads into the flue gas stack downstream of the CO2 capture device.
• the CO2 capture unit is designed to withstand the flue gases even when it is not in operation, for example an absorption unit, which is designed to run dry.
• bypass of the CO2 capture unit can be foreseen, which allows to operate the power plant independent of the CO2 capture unit.
• This bypass can also be advantageous for start-up or shut down of the plant as well as for plant operation during maintenance of the CO2 capture system.
• a storage tank dimensioned to supply CO2 absorbent for a defined period of time is provided, which allows continuous CO2 capture even when the CO2 compression and resorption are off during an under- frequency event.
• CO2 capture system is a complex system
• an appropriate control system is required as discussed for the different operating methods above.
• This control system is depending on and affecting the power control of the plant.
• the power control is an essential part of the plant control system it is advantageous to integrate the control of the CO2 capture system into plant control system or to coordinate the control of the CO2 capture system by the plant control system and to connect all the relevant data lines to the plant control system. If the plant consists of several units and the plant control system has a hierarchical structure consisting of plant controller and unit master controllers, it is advantageous to realize such an integration or coordination of the CO2 capture system's control into each units ' master controller.
• the CO2 capture system has its own controller, which is connected to the plant control system via a direct data link.
• the plant control system or the unit master controller has to send at least one signal to the controller of the CO2 capture plant.
• This signal can for example be a commanded power consumption signal or a commanded capture rate.
• the CO2 capture controller is not necessarily one hardware device but can be decentralized into drive and group controllers coordinated by one or more control units.
• the high-level control unit can for example send the total commanded mass flow to the CO2 compression unit's group controller and receive the total actual mass flow as input from this group controller.
• the compression unit in this example contains several compressor trains. Each of the compressor trains has its own device controller.
• the group controller has an algorithm to decide how to best distribute the commanded total CO2 compression mass flow on the different compressor trains and sends a commanded mass flow to each individual compressor train's device controller. In return, the group controller gets the actual CO2 compression mass flow of each compressor train.
• Each compressor train device controller can again work with depended controllers on lower levels.
• Fig. 1 is a schematic view of a power plant with CO2 capture and compression.
• Fig. 2 schematically shows power output variations for a power plant with a flexible operation method for CO2 capture and compression during an under- frequency response event.
• Fig. 3 schematically shows power output variations for a power plant with a flexible operation method for CO2 capture and compression during an under- frequency response event, combined with a correction of the plant gross output.
• Fig. 4 schematically shows power output variations for a power plant with a flexible operation with for CO2 capture and compression during an under- frequency response event, in which the additional net power requirements of the grid are met by trips of the CO2 capture and compression systems.
• a power plant for execution of the proposed method consists mainly of a conventional power plant 1 plus a CO2 capture unit 2 and a CO2 compression unit 9.
• a typical arrangement with post combustion capture is shown in Fig. 1.
• the power plant 1 is supplied with air 3 and fuel 4. Its main outputs are the plant gross electric power A and flue gas 15. Further, steam is extracted from the plant 1 and supplied via the steam line 13 and the steam control valve 14 to the CO2 capture unit 2. The steam is returned to the plant 1 at reduced temperature or as condensate via the return line 6 where it is reintroduced into the steam cycle.
• a CO2 capture unit 2 typically consists of a CO2 absorption unit, in which CO2 is removed from the flue gas by an absorbent, and a regeneration unit, in which the CO2 is released from the absorbent.
• a flue gas cooler might also be required.
• the CO2 depleted flue gas 16 is released from the CO2 capture unit to a stack. In case the CO2 capture unit 2 is not operating, it can be bypassed via the flue gas bypass 1 1.
• the captured CO2 will be compressed in the CO2 compressor 9, and the compressed CO2 10 will be forwarded for storage or further treatment.
• Electric power 7 is required to drive auxiliaries of the CO2 capture unit 2, and electric power 8 is used to drive the CO2 compression unit 9.
• the net power output D to the grid is therefore the gross plant output A reduced by the electric power for plant auxiliaries 17, reduced by the electric power for CO2 compression unit 8, and by the electric power for the CO2 capture unit 7.
• the corresponding control unit 18, which integrates the control of the additional components needed for the CO2 capture and compression with the control of the power plant is also depicted in Fig. 1.
• the control unit 18 has the required at least one control signal line 22 with the power plant 1 , and at least one control signal line with the CO2 compression unit 9. Further, the at least one control signal line 19 with the CO2 capture unit 2 including the flue gas bypass 1 1 is indicated.
• a regeneration unit is part of the system and correspondingly at least one signal line 20 to the regeneration unit is required.
• the capture unit 2 also includes at least one storage tank for an adsorbent/ absorbent control signal lines 21 to the storage system is required.
• the steam control valve 24 is controlled via the control signal lines 24. This control line is connected to the resorption unit, which is part of the capture unit 2, or directly to the control system 18.
• net power D is explained using two examples, in which an increase in net power output D is required for frequency response starting from an operating point where all components operate at full capacity:
• the net output D is first increased by a controlled reduction in the power consumption of the CO2 compressor unit 9.
• the power consumption of the compressor unit 9 is reduced, the amount of CO2 released from the CO2 regeneration unit 2 stays constant.
• the net output D is increased by a controlled reduction in the power consumption of the CO2 regeneration unit.
• the net output D is increased by a controlled reduction in the power consumption of the CO2 absorption unit and, if applicable, of a flue gas cooler.
• the flue gas bypass 1 1 for the CO2 capture unit 2 has to be opened as a function of the power available for the absorption unit.
• the net output D is increased by a controlled and coordinated reduction in the power consumption of all components of the CO2 capture unit 2 and compression unit 9.
• the target is to maximize the CO2 capture rate at reduced power consumption.
• the capacity of all components is reduced simultaneously at the same rate, and the CO2 flow through all components is the same.
• the power consumption is varied as a function of the capture rate.
• a feedback form these components is required and a closed loop control is advantageous.
• the flue gas bypass for the CO2 capture unit 1 1 has to be opened as a function of the power available for the absorption unit 2.
• Fig. 2 an example for an under- frequency event with the optimized operation method of a power plant with CO2 capture and compression is shown over time.
• T Os the plant is in normal operation at base load with the CO2 capture and compression system in operation.
• the impact of the plant auxiliaries and main power consumers of the CO2 capture system on the plant net power output D is show by indicating the relative output P 1 - at different stages of the plant.
• All power outputs shown in this Figure are normalized by plant gross power output A at base load with steam extraction for resorption.
• A' is the gross output without steam extraction for resorption.
• B is the gross output reduced by the plant auxiliaries.
• C is the output after the output B is further reduced by CO2 compression.
• D is the resulting plant net power output after C is reduced by the power consumption of the absorption.
• the normalized grid frequency F G is the frequency normalized with the nominal grid frequency, which is typically either 50 Hz or 60 Hz.
• the power reductions from B to C, and C to D as well as the gross power increase from A to A' are used to control the net output D during an under- frequency event.
• the net power D is kept constant as the normalized grid frequency F G drops from 100% to 99.8% during the time period from 20s to 30s because the controller has a 0.2% dead band, in which it does not react to deviations from design frequency.
• Fig. 3 a second under- frequency event with the optimized operation method of a power plant with CO2 capture and compression is shown over time.
• T Os the plant is in normal operation at base load with the CO2 capture and compression system in operation.
• Fig. 4 shows a third example for power output variations of a power plant with a flexible operation method for CO2 capture and compression during an under- frequency response event.
• the additional net power requirements of the grid are met by sudden shut downs or trips of the CO2 capture and compression system's components.
• the power used for recompression of flue gasses as used in case of cryogenic CO2 separation or in case of absorption on elevated pressure levels can be saved or reduced during times of high power demand.
• the cooling power can be saved or reduced during an under- frequency event.
• any under- frequency event will lead to a reduction of the gas turbine gross power output, if no countermeasures are taken.
• an over firing that is an increase of the hot gas temperature beyond the design temperatures, is carried out for frequency response in gas turbines.
• the standard measures for frequency response can be combined with the features described for power plants with CO2 capture and compression.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
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• General Engineering & Computer Science (AREA)
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• 2008
  • 2008-01-11 EP EP08100390A patent/EP2078828A1/en not_active Withdrawn
• 2009
  • 2009-01-09 PL PL09701263T patent/PL2232018T3/pl unknown
  • 2009-01-09 ES ES09701263.7T patent/ES2612742T3/es active Active
  • 2009-01-09 WO PCT/EP2009/050205 patent/WO2009087210A2/en not_active Ceased
  • 2009-01-09 JP JP2010541788A patent/JP6188269B2/ja active Active
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  • 2009-01-09 CN CN200980101948.3A patent/CN101910568B/zh active Active
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