Coal fired oxy plant with air separation unit including parallel coupled heat exchanger

Abstract

A coal fired Oxy boiler power plant having a combustion system configured to burn coal using an oxygen stream to produce a flue gas stream, a CO2 capture system connected to the flue gas stream and a steam cycle with serially arranged low pressure heaters forming part of a condensate system. The combustion system includes, an Air Separation Unit for removing N2 from air to produce the oxygen stream for the boiler. The Air Separation Unit includes an Air Separation Unit heat exchanger that is thermally and fluidly connected to the condensate system so as to be fluidly parallel to at least one serial low pressure heater and fluidly parallel to at least one less that the total number of serial low pressure heaters. The Flue Gas Heat Recovery System, Flue Gas Condenser and Gas Processing unit are thermally integrated into the condensate system.

Claims

1. A coal fired Oxy boiler power plant having: a combustion system comprising: an Air Separation Unit, for removing N2 from air to produce an oxygen stream, having an Air Separation Unit heat exchanger to remove thermal energy from the Air Separation Unit; a steam boiler configured to burn coal by using the oxygen stream to produce a flue gas stream; a CO2 capture system configured and arranged to remove CO2 from the flue gas stream; a steam power plant with a condensate system comprising: a condenser for condensing steam; a plurality of serial low pressure heaters, arranged in series and sequentially in a direction of a condensate flow, configured and arranged to receive the condensate from the condenser; a feed water tank configured and arranged to receive condensate from the serial low pressure heaters; the CO2 capture system comprising: a Flue Gas Heat Recovery System heat exchanger, having a Flue Gas Heat Recovery System heat exchanger condensate line having: a first end fluidly connected between a first of the serial low pressure heaters and a second of the serial low pressure heaters, and also fluidly connected between the first of the serial low pressure heaters and the condenser; and a second end fluidly connected between a third of the serial low pressure heaters and a fourth of the serial low pressure heaters, and also fluidly connected to the condenser through a valve enabled to enable flow of condensate to the condenser when closed; wherein the Air Separation Unit heat exchanger is thermally and fluidly connected to the condensate system by an Air Separation Unit heat exchanger condensate line so as to be fluidly parallel to at least one of the serial low pressure heaters and fluidly parallel to at least one less than a total number of the serial low pressure heaters, and so as to heat the condensate using the thermal energy from the Air Separation Unit.

2. The coal fired Oxy boiler power plant of claim 1 wherein the Air Separation Unit heat exchanger is fluidly connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a third of the serial low pressure heaters and a fourth of the serial low pressure heaters.

3. The coal fired Oxy boiler power plant of claim 1 wherein the Air Separation Unit heat exchanger condensate line is fluidly connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a fourth of the low pressure heaters and the feed water tank.

4. The coal fired Oxy boiler power plant of claim 1 wherein the Air Separation Unit heat exchanger condensate line is fluidly connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a second of the serial low pressure heaters and a third of the serial low pressure heaters.

5. The coal fired Oxy boiler power plant of claim 1 wherein the Air Separation Unit heat exchanger condensate line is fluidly connected to the condensate system at a location which is: between a first of the serial low pressure heaters and a second of the serial low pressure heaters; and between a third of the serial low pressure heaters and a fourth of the serial low pressure heaters.

6. The coal fired Oxy boiler power plant of claim 1 wherein the Air Separation Unit heat exchanger condensate line is fluidly connected to the condensate system at a location which is: between a first of the serial low pressure heaters and a second of the serial low pressure heaters; and between a fourth of the serial low pressure heaters and the feed water tank.

7. The coal fired Oxy boiler power plant of claim 1 comprising: a condensate flow control valve, in the condensate system, located fluidly at a location which is: between the first end and the second end of the Air Separation Unit heat exchanger condensate line; and between the first end and the second end of the Flue Gas Heat Recovery System heat exchanger condensate line.

8. The coal fired oxy boiler power plant of claim 1 wherein the Flue Gas Heat Recovery System condensate line includes a reverse flow prevention means fluidly upstream of the second end.

9. The coal fired oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Flue Gas Condenser, for removing condensables from the flue gas stream, having a Flue Gas Condenser condensate line connected to the condensate system at a location which is at: a first end at a point upstream of a first of the serial low pressure heaters; and at a second end at a point between the first of the serial low pressure heaters and the first end of the Flue Gas Condenser condensate line, a bypass valve being located between the first end of the Flue Gas Condenser condensate line and the second end of the Flue Gas Condenser condensate line.

10. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: between a first of the serial low pressure heaters and a second of the serial low pressure heaters; and between a fifth of the serial low pressure heaters and the Feed Water Tank.

11. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: between a first of the serial low pressure heaters and a second of the serial low pressure heaters; and between a fourth of the serial low pressure heaters and a fifth of the serial low pressure heaters.

12. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system further comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: between a first of the serial low pressure heaters and a second of the serial low pressure heaters; and between a third of the serial low pressure heaters and a fourth of the serial low pressure heaters.

13. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a fourth of the serial low pressure heaters and the Feed Water Tank.

14. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a third of the serial low pressure heaters and a fourth of the serial low pressure heaters.

15. The coal fired Oxy boiler power plant of claim 1 wherein the CO2 capture system comprises: a Gas Processing Unit heat exchanger having a Gas Processing Unit condensate line connected to the condensate system at a location which is: upstream of a first of the serial low pressure heaters; and between a second of the serial low pressure heaters and a third of the serial low pressure heaters.

16. The coal fired Oxy boiler power plant of claim 10 further comprising: a condensate flow control valve, in the condensate system, located fluidly: parallel to the Air Separation Unit heat exchanger; and parallel to the Gas Processing Unit heat exchanger.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) By way of example, an embodiment of the present disclosure is described more fully hereinafter with reference to the accompanying drawings, in which:

(2) FIG. 1 is a flow diagram of a patent of the prior art; and

(3) FIGS. 2 to 13 are flow diagrams of exemplary embodiments showing the integration of different CO2 capture system heat integration schemes in a coal fired Oxy Boiler plant that are adapted to complement the thermal integration of an Air Separation Unit into condensate system of the Oxy Boiler plant.

DETAILED DESCRIPTION

(4) Exemplary embodiments of the present disclosure are now described with references to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the disclosure. However, the present disclosure may be practiced without these specific details, and is not limited to the exemplary embodiments disclosed herein.

(5) Exemplary embodiments shown in FIGS. 2 to 13 are applied to an oxy-combustion plant having an oxy fired boiler 42 with an integrated CO2 capture system for polishing flue gas emitted from the boiler and separating CO2 therefrom in a Gas Processing Unit and steam/water Rankine cycle configured to generate electrical power. The steam/water cycle includes a condenser extraction pump arrangement having a first stage 1 connected to a condenser 2 outlet and a second stage 3 located at the outlet of a Condensate Polishing Plant 4. This arrangement is located upstream of a condensate heating train consisting of serially arranged low pressure heaters 6, 7, 8, 9, 31. Heated condensate from low pressure heaters 6, 7, 8, 9, 31 is feed into a Feed water tank 36.

(6) The oxy-combustion plant further includes an Air Separation Unit for removing nitrogen from air to produce an oxygen rich stream to be fed to the boiler 42. Thermal energy from the Air Separation Unit is advantageously removed in an Air Separation Unit heat exchanger 11 by heating condensate extracted from the condensate system so as to bypass at less one of the low pressure heaters 6, 7, 8, 9, 31 such that the Air Separation Unit heat exchanger 11 is fluidly parallel to at least one less that the total number of low pressure heaters.

(7) In a further exemplary embodiment shown in FIG. 2, the oxy combustion plant comprises at least five serial low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series and the Air Separation Unit is fluidly connected to the condensate system at a point upstream of the first of the serial low pressure heaters 6 as well as at a point between the third of the serial low pressure heaters 8 and the fourth of the serial low pressure heaters 9. In this way, condensate passing through the Air Separation Unit heat exchanger 11 bypasses three of the serial low pressure heaters 6, 7, 8.

(8) In a further alternate exemplary embodiment shown in FIG. 3, the oxy combustion plant comprises at least five serial low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series and the Air Separation Unit is fluidly connected to the condensate system at a point upstream of the first of the serial low pressure heaters 6 as well as at a point between the fourth of the serial low pressure heaters 9 and the fifth of the serial low pressure heaters 31. In this way, condensate passing through the Air Separation Unit heat exchanger 11 bypasses four of the serial low pressure heaters 6, 7, 8, 9.

(9) In a further alternate exemplary embodiment shown in FIG. 4, the oxy combustion plant comprises at least five serial low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series and the Air Separation Unit is fluidly connected to the condensate system at a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7 as well as at a point between the third of the serial low pressure heaters 8 and the fourth of the serial low pressure heaters 9. In this way, condensate passing through the Air Separation Unit heat exchanger 11 bypasses two of the serial low pressure heaters 6, 7.

(10) In a further alternate exemplary embodiment shown in FIG. 5, the oxy combustion plant comprises at least five low pressure heaters arranged in a condensate flow series and the Air Separation Unit is fluidly connected to the condensate system at a point between the first of the serial low pressure heaters and the second of the serial low pressure heaters as well as at a point between the fourth of the serial low pressure heaters 9 and the fifth of the serial low pressure heaters 31. In this way condensate passing through the Air Separation Unit heat exchanger bypasses three of the serial low pressure heaters 7, 8, 9, preferably the second, third and fourth of the serial low pressure heaters 7, 8, 9.

(11) In alternative exemplary embodiments shown in FIGS. 11 to 13, the oxy combustion plant comprises only 4 serial low pressure heaters 6, 7, 8, 9 instead of at least 5. The choice between having either 4 or at least 5 serial low pressure heaters 6, 7, 8, 9, 31 depends on the application of the Flue Gas Condenser and the decision to privilege the capture operation or not,

(12) Each of the alternate exemplary embodiments makes it possible to match temperatures of the Air Separation Unit to the condensate system thus ensuring optimum heat recovery defined by a combination of outlet temperature and recovery duty criteria thus leading to maximum net energy transfer.

(13) In an exemplary embodiment shown in FIG. 6, the coal fired Oxy boiler power plant comprises a plurality of low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series while the CO2 capture system comprises a Flue Gas Condenser 16, for removing condensables from the flue gas stream. The Flue Gas Condenser 16 further includes a Flue Gas Condenser condensate line 14 connected to the condensate system at a first end upstream of the first of the serial low pressure heaters 6 and at a second end between the first of the serial low pressure heaters 6 and second of the serial low pressure heaters 7. In this arrangement, the condensate system further includes a bypass valve 15 between the first of the serial low pressure heaters 6 and the first end of the Flue Gas Condenser condensate line 14 so that, when the bypass valve 15 is closed, condensate fully bypasses the first of the serial low pressure heater 6.

(14) It was found that this particular arrangement enables efficient operation if the oxy-combustion plant is operated in air mode, for example, during start-up, or if the Flue Gas Condenser 16 needs to be taken offline for maintenance. Although this embodiment is shown with an Air Separation Unit heat exchanger 11 arrangement equivalent to that shown in FIG. 2, the embodiment may be applied to other Air Separation Unit heat exchanger 11 arrangements, including those shown in FIG. 3, 4 or 5.

(15) In further exemplary embodiments shown in FIGS. 11 to 13, the condensate system does not include any serial low pressure heaters between the first end and the second end of the Flue Gas Condenser condensate line 14. In this arrangement, the first of the serial low pressure heaters 6 is located downstream of the second end of the Flue Gas Condenser condensate line 14 and the total number of the serial low pressure heaters is typically four. The flow rate of condensate through the Flue Gas Condenser condensate line 14 is controllable by the bypass valve 15 located in the condensate system between the first and second ends of the Flue Gas Condenser condensate line 14.

(16) In an exemplary embodiment shown in FIG. 2 the coal fired oxy boiler plant, in addition to a condensate system having at least four serial low pressure heaters 6, 7, 8, 9, 31, includes a CO2 capture system with a Flue Gas Heat Recovery System 40 for recovering heat from the flue gas. The Flue Gas Heat Recovery System further includes a primary heat recovery loop 39 adapted to flow, in a closed loop, a heat transfer medium through the Flue Gas Heat Recovery System so that the transfer medium exchanges thermal energy with flue gas. Included in the primary heat recover loop 39 is a Flue Gas Heat Recovery System heat exchanger 22 with a Flue Gas Heat Recovery System heat exchanger condensate line 19 fluidly connected at a first end to the condensate system at a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7, and at a second end further connected to the condensate system at a point between the third of the serial low pressure heaters 8 and the fourth of the serial low pressure heaters 9.

(17) In a further exemplary embodiment shown in FIG. 2, a control valve 38 is located in the condensate system fluidly between the third of the serial low pressure heaters 8 and the fourth of the serial low pressure heaters 9 at a point upstream of the second end of the Flue Gas Heat Recovery System heat exchanger condensate line 19 and the second end of the Air Separation Unit heat exchanger condensate line 5. This makes it possible to control the ratio of condensate flow between through the Flue Gas Heat Recovery System heat exchanger 22, the Air Separation Unit heat exchanger 11, and upstream serial low pressure heaters 6, 7, 8.

(18) In an exemplary embodiment shown in FIG. 7 the coal fired oxy boiler plant, in addition to a condensate system having at least four serial low pressure heaters 6, 7, 8, 9, 31 includes a CO2 capture system with a Flue Gas Heat Recovery System 40 for recovering heat from the flue gas. The Flue Gas Heat Recovery System further includes a primary heat recovery loop 39 adapted to flow, in a closed loop, a heat transfer medium through the Flue Gas Heat Recovery System so that the transfer medium exchanges thermal energy with flue gas. Included in the primary heat recover loop 39 is a Flue Gas Heat Recovery System heat exchanger 22 with a Flue Gas Heat Recovery System heat exchanger condensate line 19 that is fluidly connected at a first end to the condensate system at a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7 and, at a second end, further connected to the condensate system at a point between the fourth of the serial low pressure heaters 9 and the fifth of the serial low pressure heaters 31.

(19) In a further exemplary embodiment shown in FIG. 7, a control valve 38 is located in the condensate system fluidly between the third of the serial low pressure heaters 8 and the fourth of the serial low pressure heaters 9 at a point upstream of the second end of the Air Separation Unit heat exchanger condensate line 5. This makes it possible to control the ratio of condensate flow between through the Flue Gas Heat Recovery System heat exchanger 22, the Air Separation Unit heat exchanger 11, and upstream serial low pressure heaters 6, 7, 8.

(20) In an exemplary embodiment shown in FIG. 8, for emergency/protection reasons, the plant includes a first fluid line 23 and a second fluid line 25. The first fluid line 23 has a first end connected to the condensate system between the first of the serial low pressure heaters 6 and a condensate extraction pump second stage 3 located downstream of the condenser 2 and a second end connected to the Flue Gas Heat Recovery System condensate line 19 upstream of the Flue Gas Heat Recovery System heat exchanger 22. In an exemplary embodiment in which the plant includes a Flue Gas Condenser the first fluid line 23 has a first end connected to the condensate system between the first end of the Flue Gas Condenser condensate line 14 and a condensate extraction pump second stage 3 located downstream of the condenser 2 and a second end connected to the Flue Gas Heat Recovery System condensate line 19 upstream of the Flue Gas Heat Recovery System heat exchanger 22. The first fluid line 23 includes a valve 24 that is closed during normal operation and open in emergency operation for thermal protection of the Flue Gas Heat Recovery System. When emergency protection is activated, to prevent backflow of condensate through the Flue Gas Heat Recovery System condensate line 19 into the Flue Gas Condenser condensate line 14, the Flue Gas Heat Recovery System condensate line 19 includes a reverse flow prevention means, such as a mechanical or actuated non-return valve, in the Flue Gas Heat Recovery System condensate line 19, fluidly upstream of the first fluid line 23 second end. The second fluid line 25 connects the Flue Gas Heat Recovery System heat exchanger with the condenser 2 and includes a valve 26 that is closed during normal operation and open in emergency operation for thermal protection of the Flue Gas Heat Recovery System. When emergency protection is activated, to ensure that condensate flows to the condenser 2, a valve 29 is located in the Flue Gas Heat Recovery System condensate line 19 fluidly between the second end of the Flue Gas Heat Recovery System condensate line 19 and the second fluid line 25. When closed for emergency protection this enables the flow of condensate from the Flue Gas Heat Recovery System condensate line 19 to the condenser 2.

(21) In further exemplary embodiment shown in FIG. 9, the coal fired Oxy boiler power plant comprises five low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series. The CO2 capture system comprises a Flue Gas Condenser 16 downstream of the Flue Gas Heat Recovery System 40 and a Gas Processing Unit heat exchanger 33 for cooling of compressed rich-CO2 flue-gas before separation of CO2. The Flue Gas Condenser 16 includes a Flue Gas Condenser condensate line 14 connected to the condensate system at a first end upstream of the first of the serial low pressure heaters 6 and at a second end connected to a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7. The Gas Processing Unit heat exchanger 33 has a Gas Processing Unit condensate line 30 connected at a first end to the condensate system at a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7 and connected at a second end to the condensate system at a point fluidly between the fifth of the serial low pressure heaters 31 and the Feed Water Tank 36.

(22) In further exemplary embodiment shown in FIG. 10, the coal fired Oxy boiler power plant comprises at least four low pressure heaters 6, 7, 8, 9, 31 arranged in a condensate flow series. The CO2 capture system comprises a Flue Gas Condenser 16 downstream of the Flue Gas Heat Recovery System 40 and a Gas Processing Unit heat exchanger 33 for cooling of compressed rich-CO2 flue-gas before separation of CO2. The Flue Gas Condenser 16 includes a Flue Gas Condenser condensate line 14 connected to the condensate system, at a first end, upstream of the first of the serial low pressure heaters 6 and, at a second end, to a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7. The Gas Processing Unit heat exchanger 33 has a Gas Processing Unit condensate line 30 connected, at first end, to the condensate system at a point between the first of the serial low pressure heaters 6 and the second of the serial low pressure heaters 7 and connected, at a second end, to the condensate system at a point between the fourth of the serial low pressure heaters 9 and the fifth of the serial low pressure heaters 31.

(23) In an exemplary embodiment shown in FIGS. 11 to 13, the coal fired oxy boiler power plant has four low pressure heaters 6, 7, 8, 9 while the CO2 capture system further comprises a Flue Gas Condenser 16 having a Flue Gas Condenser condensate line 14 connected at first and second ends upstream of the of the first of the serial low pressure heaters 6. A bypass valve 15, for controlling the quantity of condensate flowing through the Flue Gas Condenser, is located between the ends of the Flue Gas Condenser condensate line 14. The Gas Processing Unit condensate line 30 may be connected to the condensate system at different points. For example, in an exemplary embodiment shown in FIG. 2 first and second end of the Gas Processing Unit condensate line 30 are connected to a point between a first of the serial low pressure heaters 6 and a second of the serial low pressure heaters 7 and a point between a fourth of the serial low pressure heaters 9 and a fifth of the serial low pressure heaters 31 respectively.

(24) In another exemplary embodiment shown in FIG. 3, first and second ends of the Gas Processing Unit condensate line 30 are connected to a point between a first of the serial low pressure heaters 6 and a second of the serial low pressure heaters 7 and a point between a third of the serial low pressure heaters 8 and a fourth of the serial low pressure heaters 9.

(25) In another exemplary embodiment shown in FIG. 11, first and second ends of the Gas Processing Unit condensate line 30 are connected to a point upstream of a first of the serial low pressure heaters 6 and at a point between a fourth of the serial low pressure heaters 9 and the Feed Water Tank 36.

(26) In another exemplary embodiment shown in FIG. 12 first and second ends of the Gas Processing Unit condensate line 30 are connected to a point upstream of a first of the serial low pressure heaters 6 and at a point between a third of the serial low pressure heaters 8 and a fourth of the serial low pressure heaters 9.

(27) In another exemplary embodiment shown in FIG. 13, first and second ends of the Gas Processing Unit condensate line 30 are connected to a point upstream of a first of the serial low pressure heaters 6 and at a point between a second of the serial low pressure heaters 7 and a third of the serial low pressure heaters 8. In order to globally control the flow of condensate through the CO2 capture system heat exchangers and the Air Separation Unit heat exchanger, a control valve 38 is located in the condensate system fluidly between the serial low pressure heaters 6, 7, 8, 9, 31 immediately upstream of the second ends of the condensate lines 5, 19, 30 of the Air Separation Unit heat exchanger 11, the Flue Gas Heater Recovery System heat exchanger 22 and the Gas Processing Unit heat exchanger 33.

(28) Although the disclosure has been herein shown and described in what is conceived to be the most practical exemplary embodiment, it will be appreciated by those skilled in the art that the present disclosure can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, although heat exchangers are referenced in the singular each system may include multiple heat exchangers fluidly connected to the condensate system arranged either parallel or in series. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the disclosure is indicated by the appended claims rather that the foregoing description and all changes that come within the meaning and range and equivalences thereof are intended to be embraced therein.

REFERENCE NUMBERS

(29) 1 Condenser Extraction pump first stage 2 Condenser 3 Condenser Extraction pump second stage 4 Condensate polishing plant 5 Air Separation Unit heat exchanger condensate line 6 Low Pressure heater #1 7 Low Pressure heater #2 8 Low Pressure heater #3 9 Low Pressure heater #4 11 Air Separation Unit heat exchanger 14 Flue Gas Condenser condensate line 15 Bypass valve 16 Flue Gas Condenser 19 Flue Gas Heat Recovery System heat exchanger condensate line 22 Flue Gas Heat Recovery System heat exchanger 23 Fluid line 24 Valve 25 Fluid line 26 Valve 29 Valve 30 Gas Processing Unit heat exchanger condensate line 31 Low Pressure heater#5 32 High pressure heaters 33 Gas Processing Unit heat exchanger 36 Feed water tank 38 Control valve 40 Flue Gas Heat Recovery System 42 Boiler HP High Pressure steam turbine IP Intermediate pressure steam turbine LP Low pressure steam turbine