Systems and methods for power production using nested CO.SUB.2 .cycles
11174759 · 2021-11-16
Assignee
Inventors
Cpc classification
F02C3/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2230/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C6/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/04133
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/04145
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E20/16
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
F01K23/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K23/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E20/34
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
F25J2240/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/04618
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/103
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/04018
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/04024
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/007
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K7/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2260/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01K23/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K23/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K7/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01K25/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C1/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C6/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present disclosure relates to systems and methods useful for power production. In particular, a power production cycle utilizing CO.sub.2 as a working fluid may be combined with a second cycle wherein a compressed CO.sub.2 stream from the power production cycle can be heated and expanded to produce additional power and to provide additional heating to the power production cycle.
Claims
1. A method of power production comprising: carrying out a first cycle that includes: expanding a work stream comprising recycled CO.sub.2 across a first turbine to produce a first quantity of power; withdrawing heat from the work stream in a recuperative heat exchanger; compressing the work stream; reheating the work stream using withdrawn heat in the recuperative heat exchanger; and superheating the compressed work stream in a combustor; and carrying out a nested cycle wherein compressed work stream from the first cycle is heated with a heat source that is independent of the combustor and the recuperative heat exchanger and is expanded across a second turbine to produce a second quantity of power.
2. The method of power production of claim 1, wherein the expanded work stream from the nested cycle is used to add heat to the work stream in the first cycle after the compressing and before the superheating.
3. The power production method of claim 1, wherein the heat source in the nested cycle is one or more of a combustion heat source, a solar heat source, a nuclear heat source, a geothermal heat source, and an industrial waste heat source.
4. A method for improving the efficiency of a power production cycle, the method comprising: operating the power production cycle so that compressed, recycled CO.sub.2 is passed through a combustor wherein a carbonaceous fuel is combusted with an oxidant to produce an exhaust stream comprising the compressed, recycled CO.sub.2; the exhaust stream is expanded across a turbine to produce power and form a turbine exhaust stream comprising the recycled CO.sub.2; the turbine exhaust stream is cooled in a recuperative heat exchanger; the cooled turbine exhaust stream is passed through a separator to separate the recycled CO.sub.2; the recycled CO.sub.2 is compressed; and the compressed recycled CO.sub.2 is split into a first portion and a second portion with the first portion being heated by passage through the recuperative heat exchanger against the turbine exhaust stream; and adding further heating to the compressed recycled CO.sub.2 above the level of heating that is available from the turbine exhaust stream, the further heating being provided by heating the second portion of the compressed recycled CO.sub.2 with a heat source that is independent of the power production cycle and expanding across a second turbine to produce a second quantity of power, and transferring heat from the heated, second portion of the compressed recycled CO.sub.2 to the first portion of the compressed recycled CO.sub.2 in the power production cycle.
5. The method of claim 4, comprising passing the heated, second portion of the compressed recycled CO.sub.2 through the recuperative heat exchanger so as to transfer heat to the first portion of the compressed recycled CO.sub.2 therein.
6. The method of claim 4, comprising passing the heated, second portion of the compressed recycled CO.sub.2 through a secondary heat exchanger to add the further heating thereto.
7. The method of claim 6, wherein after passage through the secondary heat exchanger, the heated, second portion of the compressed recycled CO.sub.2 is combined with the first portion of the compressed recycled CO.sub.2 in the recuperative heat exchanger.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Having thus described the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
(2)
(3)
DETAILED DESCRIPTION
(4) The present subject matter will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art. Indeed, the subject matter can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.
(5) The present disclosure provides systems and methods wherein a first power production cycle utilizing CO.sub.2 as a work stream can be combined with a second, or nested, power production cycle wherein a least a portion of the same CO.sub.2 work stream can be subjected to additional treatment resulting in additional power production and/or heat production. In such systems and methods, high efficiencies can be achieved. In particular, recuperative heat exchange in the first power production cycle can be improved while added power production can be simultaneously achieved. The additional treatment in the second power production cycle can include heating with a heat source that is independent of any heating utilized in the first power production cycle. The combination of the second power production cycle with the first power production cycle can be beneficial at least in part because of the ability to overlap the cycles so that one or more pieces of machinery may be utilized in both cycles. For example, a compressor utilized in the first power production cycle can also be used as the compressor in the second power production cycle. The present disclosure thus may be characterized in relation to the combination of at least one directly heated flow of CO.sub.2 and at least one indirectly heated flow of CO.sub.2 that utilize shared turbo-machinery to provide at least the benefit of increased power output while simultaneously performing optimization of a recuperative heat exchanger. The indirectly heated flow of CO.sub.2 can, in some embodiments, comprise at least a portion of the CO.sub.2 from the directly heated flow. Thus, a single recycle CO.sub.2 stream can be subject to compression to form a high pressure stream as defined herein, split into a stream that is indirectly heated and a stream that is directly heated, and recombined after the respective heating steps. Alternatively, a single recycle CO.sub.2 stream can be subject to compression to form a high pressure stream, a portion of the high pressure recycle CO.sub.2 stream can be indirectly heated to form an indirectly heated CO.sub.2 stream, and the indirectly heated CO.sub.2 stream can be combined with the remaining recycle CO.sub.2 stream to form a total recycle CO.sub.2 stream that is subject to direct heating.
(6) In some embodiments, a high pressure stream from a first power production cycle (e.g., a high pressure recycle CO.sub.2 stream) can be heated by an independent heat source in a second power production cycle. The heated stream can then be supplied to an expander adapted for power production. The expanded stream can then be inserted back to the first power production cycle in a variety of manners that beneficially can impart heating to the first power production cycle beyond heating that is available through recuperation from a cooled turbine exhaust stream. The discharge pressure from the expander in the second power production cycle can be adapted so that the expanded stream may be inserted to the first power production cycle at the appropriate pressure for the point of insertion. Heating provided to the first power production cycle in this manner can be added in a variety of manners. For example, the expanded stream from the second power production cycle may be used directly (in part or in total) as a heating stream in a recuperative heat exchanger wherein high pressure recycle CO.sub.2 is being re-heated prior to entry to a combustor in the first power production cycle. As an alternative example, the expanded stream from the second power production cycle may be used indirectly, such as being used as a heating stream in a further heat exchanger whereby a separate stream is heated for use as a heating stream in the recuperative heat exchanger.
(7) A power production cycle useful as a first power production cycle according to the present disclosure can include any system and method wherein CO.sub.2 (particularly supercritical CO.sub.2—or sCO.sub.2) is used in a work stream. As a non-limiting example, U.S. Pat. No. 8,596,075 to Allam et al., which is incorporated herein by reference, describes a system and method wherein a recycle CO.sub.2 stream is directly heated and used in power production. Specifically, the recycle CO.sub.2 stream is provided at high temperature and high pressure, is provided to a combustor wherein a carbonaceous fuel is combusted in oxygen, is expanded across a turbine to produce power, is cooled in a heat exchanger, is purified to remove water and any other impurities, is pressurized, is re-heated using the heat taken from the turbine exhaust, and is again passed to the combustor to repeat the cycle. Such system and method are beneficial in that all fuel and combustion derived impurities, excess CO.sub.2, and water are removed as a liquid or a solid (e.g., ash), and there is virtually zero atmospheric emission of any streams. The system and method achieves high efficiency through, for example, the use of low temperature level (i.e., less than 500° C.) heat input after the recycle CO.sub.2 stream has been re-pressurized and before combustion.
(8) A power production cycle useful as a first power production cycle according to the present disclosure can include more steps or fewer steps than described above and can generally include any cycle wherein a high pressure recycle CO.sub.2 stream is expanded for power production and recycled again for further power production. As used herein, a high pressure recycle CO.sub.2 stream can have a pressure of at least 100 bar (10 MPa), at least 200 bar (20 MPa), or at least 300 bar (30 MPa). A high pressure recycle CO.sub.2 stream can, in some embodiments, have a pressure of about 100 bar (10 MPa) to about 500 bar (50 MPa), about 150 bar to about 450 bar (45 MPa), or about 200 bar (20 MPa) to about 400 bar (40 MPa). Reference to a high pressure recycle CO.sub.2 stream herein may thus be a CO.sub.2 stream at a pressure within the foregoing ranges. Such pressures also apply to references to other high pressure streams described herein, such as a high pressure work stream comprising CO.sub.2.
(9) In some embodiments, a power production method according to the present disclosure can comprise combining a first power production cycle with a second power production cycle. In particular, the first power production cycle can be a cycle wherein a recycled CO.sub.2 stream is subjected to repeated compression, heating, combustion, expansion for power production, and cooling. The second power production cycle can be a cycle wherein compressed recycled CO.sub.2 from the first power production cycle is heated with a heat source that is independent of the first power production cycle, expanded for power production, and recombined with the recycled CO.sub.2 stream in the first power production cycle.
(10) As a non-limiting example, a power production system 100 and method of use thereof is illustrated in
(11) A second power production cycle 150 includes a heat source 160 that may be, for example, a gas turbine that produces a high temperature, high pressure exhaust stream 162. The heated exhaust stream 162 is passed through a heat exchanger 155 wherein it is cooled against the heating second portion recycle CO.sub.2 stream 151 withdrawn from the first power production cycle 110. Although the heat source 160 is illustrated as a single element, it is understood that a plurality of heat sources may be used. For example two or more gas turbines may be used in parallel, or a combination of different types of heat sources (e.g., a gas turbine combined with a waste heat source) may be used. The cooled stream 157 exiting the heat exchanger 155 may be vented as illustrated. In other embodiments, the cooled stream may be subjected to one or more treatments. In further embodiments, the cooled stream 157 may be recycled to the heat source 160 to be again heated.
(12) The heat source 160 may be any source adapted to provide a stream at a sufficiently high temperature. In particular, the heat source may be characterized as being independent of the first power production cycle. An independent heat source may be a heat source that is external to the power production cycle and thus does not otherwise participate in the power production cycle. For example, in
(13) As non-limiting examples, the independent heat source that provides indirect heating to the recycled CO.sub.2 stream can be one or more of a combustion heat source (e.g., a gas turbine), a solar heat source, a nuclear heat source, a geothermal heat source, or an industrial waste heat source. In further embodiments, energy may be supplied using a source that is substantially non-heating but that is combined with a heat generating element. For example, a rotating element (e.g., a wind turbine) may be coupled with a heat pump.
(14) Returning to
(15) In other embodiments, the turbine exhaust stream 142 may be combined with the first portion recycle CO.sub.2 stream 138 prior to entry to the recuperative heat exchanger 142. In such embodiments, for example, further compression may be provided to second portion recycle CO.sub.2 stream 151 and/or heated second portion recycle CO.sub.2 stream 141.
(16) In still further embodiments, the turbine exhaust stream 142 may pass through a separate heat exchanger (not illustrated in
(17) The turbine exhaust stream 142 from the second power production cycle 150 is cooled by passage through the recuperative heat exchanger 125 and exits the cold end thereof as recycle CO.sub.2 stream 144 which, as illustrated, is recombined with the substantially pure recycle CO.sub.2 stream 133 exiting the separator 130. Beneficially, the turbine 165 in the second power production cycle 150 can be operated with a desired expansion ratio so that the pressure of the turbine exhaust stream 142 is sufficiently close to a required pressure at a point in the first power production cycle where the recycle CO.sub.2 stream is recombined. In some embodiments, recycle CO.sub.2 stream 144 exiting the recuperative heat exchanger 125 can be at a temperature such that further cooling is beneficial. Such cooling may occur in the separator 130, for example, when the recycle CO.sub.2 stream 144 is combined with stream 127 at a lower pressure. Alternatively, a recycle CO.sub.2 stream 144 may pass through an added cooler (not shown in
(18) The additional heating provided by the second power production cycle as exemplified above can be particularly useful to reduce or eliminate the temperature differential that otherwise exists at the hot end of the recuperative heat exchanger because of the different specific heat capacities of the turbine exhaust entering the recuperative heat exchanger and the recycle CO.sub.2 stream exiting the recuperative heat exchanger. Systems and methods as described herein are adapted to achieve such benefit by providing the necessary quantity and quality of heat as the further heating. Based on the known flow rate, pressure, and temperature of the recycle CO.sub.2 stream entering the turbine in the second power production system, an expansion ratio can be chosen that allows the recycle CO.sub.2 stream exiting the turbine in the second power production system to provide the minimum heat quantity and temperature needed by the recuperative heat exchanger in the first power production cycle.
(19) A system and method as described above creates a thermodynamic closed loop nested within a first power production cycle. The gas mixture in the nested cycle is, however, allowed to interact with the direct fired flow of recycle CO.sub.2 since both cycles can share pumping equipment, as well as condensing equipment if desired. For example, while the stream 144 is shown being combined with the stream 133 in
(20) Each of the first power production cycle and the second power production cycle may be capable of being carried out independently for power production. The combination thereof, however, provides particular benefits. In a first power production cycle such as shown in
(21) In some embodiments, the present systems and methods can be characterized as being adapted for improving the efficiency of a power production cycle. To this end, a power production cycle may be operated as otherwise described herein in relation to a first power production cycle. The power production cycle for which efficiency is improved typically can include any power production cycle whereby a working fluid comprising CO.sub.2 is repeatedly cycled at least through stages of compressing, heating, expansion, and cooling. In various embodiments, a power production cycle for which efficiency can be improved may include combinations of the following steps: combustion of a carbonaceous fuel with an oxidant in the presence of a recycled CO.sub.2 stream to provide a combustion product stream at a temperature of at least about 500° C. or at least about 700° C. (e.g., about 500° C. to about 2000° C. or about 600° C. to about 1500° C.) and a pressure of at least about 100 bar (10 MPa) or at least about 200 bar (20 MPa) (e.g., about 100 bar (10 MPa) to about 500 bar (50 MPa) or about 150 bar (15 MPa) to about 400 bar (40 MPa)); expansion of a high pressure recycled CO.sub.2 stream (e.g., at a pressure as noted above) across a turbine for power production; cooling of a high temperature recycled CO.sub.2 stream (e.g., at a pressure as noted above), particularly of a turbine discharge stream, in a recuperative heat exchanger; condensing of one or more combustion products (e.g., water) in a condenser, the combustion products being present particularly in a combustion product stream that has been expanded and cooled; separating water and/or further materials from CO.sub.2 to form a recycled CO.sub.2 stream; compressing a recycled CO.sub.2 stream to a high pressure (e.g., a pressure as noted above), optionally being carried out in multiple stages with inter-cooling to increase stream density; and heating a compressed recycled CO.sub.2 stream in a recuperative heat exchanger, particularly heating against a cooling turbine exhaust stream.
(22) As noted above, improved efficiency of a power production cycle particularly may be achieved by adding further heating to the compressed recycled CO.sub.2 above the level of heating (e.g., recuperative heating in a heat exchanger) that is available from a turbine exhaust stream. The present disclosure achieves such further heating by utilizing a portion of the recycled CO.sub.2 stream from the power production cycle. Advantageously, a nested cycle can be added to the power production cycle utilizing at least the same compression equipment as used in the power production cycle. In particularly, further heating can be provided by withdrawing a portion of the compressed recycled CO.sub.2, heating the withdrawn portion of compressed recycled CO.sub.2 with a heat source that is independent of the power production cycle, and transferring heat from the withdrawn and heated compressed recycled CO.sub.2 to the remaining portion of the compressed recycled CO.sub.2 in the power production cycle. The nested cycle thus may be substantially similar to the second power production cycle described in relation to
(23) In further embodiments, the present disclosure also relates to power production systems. In particular, such systems can comprise one or more pumps or compressors configured to compress a CO.sub.2 stream to a high pressure as described herein. The systems can comprise one or more valves or splitters configured to divide the compressed CO.sub.2 stream into at least a first portion CO.sub.2 stream and a second portion CO.sub.2 stream. The systems can comprise a first heat exchanger (or heat exchange unit comprising a plurality of sections) configured to heat the first portion CO.sub.2 stream against a high temperature turbine discharge stream and a second heat exchanger configured to heat the second portion CO.sub.2 stream against a heated stream from an external (or independent) heat source. The systems can comprise a first turbine configured to expand the first portion CO.sub.2 stream to produce power and a second turbine configured to expand the second portion CO.sub.2 stream to produce power. The systems can comprise one or more transfer elements configured to transfer heat from the heated second portion CO.sub.2 stream to the first portion CO.sub.2 stream. The systems can comprise a combustor configured to combust a carbonaceous fuel in an oxidant in the presence of the first portion CO.sub.2 stream.
(24) The systems of the present disclosure may be characterized in relation to a configuration as a primary power production system and a secondary power production system, the two systems having separate heat sources and at least one shared compression element (and optionally at least one shared condensing element. For example, a system according to the present disclosure can comprise a primary power production system including a compressor configured to compress a CO.sub.2 stream to a high pressure as described herein, a combustor downstream from the compressor, a first turbine downstream from the combustor and upstream from the compressor, and a first heat exchanger positioned to receive a stream from the compressor and to receive a separate stream from the turbine. Optionally, a separator can be positioned downstream from the first heat exchanger and upstream from the compressor. Further optionally, a compressor can be positioned upstream from the compressor and downstream from the first heat exchanger. A system according to the present disclosure also can comprise a secondary power production system including the compressor from the primary power production system, a second turbine downstream from the compressor, and a second heat exchanger positioned to receive a stream from the compressor and to receive a separate stream from an external (or independent) heat source. The system can further comprise one or more valves or splitters downstream from the compressor and upstream from each of the first heat exchanger and the second heat exchanger.
Example
(25) Embodiments of the present disclosure are further illustrated by the following example, which is set forth to illustrate the presently disclosed subject matter and is not to be construed as limiting. The following describes an embodiment of a power production system and method utilizing a nested CO.sub.2 cycle, as illustrated in
(26) A power production cycle was modeled based on the combination of a gas turbine with a power production cycle utilizing a circulating CO.sub.2 work stream, such as described in U.S. Pat. No. 8,596,075 to Allam et al., said power production cycle being referred to herein as the Allam cycle. Industrial gas turbines are efficient, low capital cost reliable systems with a long history of technical development plus large worldwide manufacturing capacity. The Allam cycle offers approximately the same efficiency as the NGCC system at the same capital cost with the advantage of capturing the whole CO.sub.2 production from natural gas as a substantially pure product at pipeline pressure typically between about 100 bar (10 MPa) and about 200 bar (20 MPa). In the exemplary embodiment, a gas turbine is integrated with the Allam cycle by eliminating the entire steam power system of an NGCC plant and utilizing the hot gas turbine exhaust to provide heat for additional power generation using the CO.sub.2 working fluid from the Allam cycle plus providing the required low temperature heat input into the Allam cycle to achieve maximum efficiency. This combination allows for maintaining high efficiency for the integrated system while also providing lower capital cost per Kw of installed capacity. In some embodiments, the combination of the present disclosure can be accompanied by a substantially insignificant drop in overall efficiency for the integrated system. In other embodiments, however, there can be substantially no drop in overall efficiency. In still further embodiments, the combination of the present disclosure can allow for an increase in overall efficiency for the integrated system. In the various embodiments of the present disclosure, a reduction in capital expenditures can also be a beneficial result.
(27) Briefly, in the exemplary embodiment, hot exhaust from a gas turbine is passed through a heat recovery unit similar to an HRSG which heats a stream of high pressure (e.g., 300 bar (30 MPa) to 500 bar (50 MPa)) CO.sub.2 taken as additional flow from the Allam cycle CO.sub.2 recycle compression units. The heated CO.sub.2 is passed through a power producing turbine which has a discharge pressure corresponding to the inlet pressure of the Allam cycle CO.sub.2 pump or to the inlet pressure or intermediate pressure of the CO.sub.2 cycle compressor. The discharge flow from the auxiliary turbine, which has a temperature in the range of about 200° C. to about 500° C., is then used to provide the low temperature level heating for the high pressure recycle CO.sub.2 streams in the Allam cycle plus the additional heating required in the gas turbine exhaust heat exchanger. Optionally there can be additional low grade heat input to the total high pressure CO.sub.2 streams by operating the cryogenic oxygen plant main air compressor adiabatically. This releases a portion of the auxiliary expander discharge flow to preheat the total natural gas input to the gas turbine and Allam cycle combustors. Optionally the gas turbine exhaust can be raised in temperature with additional fuel gas firing utilizing the residual oxygen content in the gas turbine exhaust. This increases the inlet temperature and power output of the auxiliary power turbine since the high pressure CO.sub.2 stream will be heated to a higher temperature in the gas turbine exhaust heater. Optionally the cooling flow required by the Allam cycle high pressure turbine at a temperature in the range of about 300° C. to about 500° C. can be heated using the auxiliary turbine exhaust flow rather than the main Allam cycle turbine exhaust flow. The auxiliary gas turbine inlet temperature can be in the range of about 500° C. to about 900° C. No special internal or film cooling or coatings for the turbine blades will be required at these temperatures.
(28) An exemplary embodiment of an integrated system is shown in
(29) TABLE-US-00001 TABLE 1 Allam Cycle Parameter 7FB NGCC System Power System Net Power Output 280.3 MW 298.2 MW Natural Gas Heat Input 488.8 MW 510.54 MW Net Efficiency 57.3% 58.41% Condenser Vacuum 1.7 inches Hg (0.835 psia) NA Gas Turbine Power 183.15 MW NA O.sub.2 Input (99.5 mol % NA 3546 MT/day at 30 bar (3 MPa)) CO.sub.2 Output (97 mol % NA 2556 MT/day purity at 150 bar)
(30) Referring to
(31) The turbine outlet stream 66 is integrated into the system to preheat the high pressure CO.sub.2 streams in an optimum manner. Stream 66 divides into 3 parts. Stream 65 enters heat exchanger 68 where it is used to preheat the natural gas streams (3a to 3, 14a to 14 and 27a to 27) to an outlet temperature of 425° C. and exit as stream 67. Stream 25 enters heat exchanger 60 where it is used to heat the 300 bar (30 MPa) 50° C. CO.sub.2 stream 36 taken from the CO.sub.2 pump 55 discharge stream 35 to produce the cooling stream 62 at 400° C. for the Allam cycle turbine 17, plus the externally heated recycle CO.sub.2 stream at 59 at 424° C., which enters the main heat exchanger 61 at an intermediate point. Stream 30 enters the 7FB exhaust cooler 58 at an intermediate point and provides additional heating in the lower temperature section, exiting as stream 32. These three separate heat exchange duties for the auxiliary gas turbine exhaust flow 66 compensate for the large increase in the specific heat of the 300 bar (30 MPa) CO.sub.2 stream at lower temperatures and cover the duties required by the total heating high pressure CO.sub.2 flow. The cryogenic air separation plant 82 produces a product oxygen stream 49 at 30 bar (3 MPa) pressure and 99.5 mol % purity. The air feed stream 83 is compressed adiabatically in an axial compressor 69 with a coupled booster air compressor 70 both driven by an electric motor 71. The whole feed air stream is compressed in 69 to 5.7 bar (0.57 MPa). The air outlet 78 at 226° C. is used to heat an inlet 300 bar (30 MPa) CO.sub.2 stream 74 from 50° C. to 220° C. in heat exchanger 73 giving outlet stream 75. This divides into two streams 76 and 77, which are introduced into intermediate points in heat exchangers 60 and 58, respectively, to provide further heat input at the lowest temperature level into the heating high pressure CO.sub.2 streams 38 and 36. The main air feed stream 80 and the boosted air stream 81 at 65 bar (6.5 MPa) pressure, following cooling to near ambient temperature, enter the ASU 82.
(32) The Allam cycle system comprises a turbine 17 with an associated combustor 13 coupled to an electric generator 16 producing an output 15. The natural gas fuel stream 11 is compressed to 320 bar (32 MPa) in a two stage intercooled compressor 12 driven by an electric motor 10. The natural gas is preheated in 68. The turbine is directly coupled to the main CO.sub.2 recycle compressor 18, which has two stages with an intercooler 19. The inlet pressure in line 21 is 29 bar (2.9 MPa) and the discharge pressure in line 22 is 67 bar (6.7 MPa). The discharge flow 22 is cooled to near ambient temperature in heat exchanger 40 giving a CO.sub.2 pump inlet flow 39 with a density of about 0.8 kg/liter. The pump discharge provides (in addition to the main CO.sub.2 recycle flow 37) additional streams 36, 38 and 74 used for integration of the 7FB gas turbine. The net CO.sub.2 produced from the combustion of the natural gas stream 14 is discharged at a pressure of 305 bar (30.5 MPa) as stream 84 for delivery to a pipeline. The main recuperative heat exchanger of the Allam cycle unit 61 cools the turbine exhaust stream 24 at 725° C. to 60° C., stream 41, which has stream 33 from the 7FB gas turbine integration system added thereto (stream 33 being a combination of stream 31 from heat exchanger 60 and stream 32 from heat exchanger 58 and stream 67 from heat exchanger 68). The combined stream 42 is cooled near ambient temperature in cooler 43 to produce stream 44 that enters separator 45 where condensed liquid water is separated, leaving as stream 46. The exit CO.sub.2 gas stream 47 at 29 bar (2.9 MPa) divides into the main recycle CO.sub.2 compressor inlet stream 21 and a stream 48 which mixes with pure oxygen stream 49 to produce an oxidant stream 50 with 25 mol % 02 content. This stream is compressed to 305 bar (30.5 MPa) in a multistage compressor 54 (with intercooler 54a) driven by an electric motor 52. The discharge stream 51 together with the recycle CO.sub.2 stream 37 are heated to 715° C. in heat exchanger 61 against the turbine exhaust stream 24 to form stream 20 entering the combustor 13 and stream 23 entering the combustor exhaust stream to moderate the turbine 17 inlet temperature to about 1150° C.
(33) The exemplified integrated system incorporates a specific model gas turbine which results in an efficient utilization of the heat available in the gas turbine exhaust. Larger and smaller gas turbines, however, can be used. Performance values based on the exemplified model are provided in Table 2.
(34) TABLE-US-00002 TABLE 2 Parameter Integrated System Total Net Power Output 594.1 MW Total Natural Gas Heat Input 1040 MW Total Net Efficiency 57.131% O.sub.2 Input (99.5 mol % at 30 bar (3 MPa)) 3546 MT/day CO.sub.2 Output (97 mol % purity at 150 bar) 2556 MT/day
(35) The exemplified system can be used for integration of existing open cycle gas turbine units that compress ambient air as their working fluid. It is equally applicable to the closed cycle gas turbines using oxy-fuel combustors with the cooled turbine exhaust being used as gas turbine compressor feed following removal of produced CO.sub.2, water inerts, and excess oxygen. For this type of gas turbine, virtually complete removal of CO.sub.2 from the system is possible. For a conventional open cycle gas turbine, only the CO.sub.2 derived from the Allam cycle can be removed for sequestration.
(36) Many modifications and other embodiments of the presently disclosed subject matter will come to mind to one skilled in the art to which this subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the present disclosure is not to be limited to the specific embodiments described herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.