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Integration of pressure swing adsorption with a power plant for CO2 capture/ … — Exxonmobil Research And Engineering Company (US9476356B2)

Exxonmobil Research And Engineering Company · Google Patents

Google Patents · Patents · License: Open Access

patent, google patents, intellectual property, US9476356B2, Exxonmobil Research And Engineering Company, Narasimhan Sundaram, en, 2016

ABSTRACT

Abstract

Systems and methods are provided for combined cycle power generation while reducing or mitigating emissions during power generation. Recycled exhaust gas from a power generation combustion reaction can be separated using a swing adsorption process so as to generate a high purity CO 2 stream while reducing/minimizing the energy required for the separation and without having to reduce the temperature of the exhaust gas. This can allow for improved energy recovery while also generating high purity streams of carbon dioxide and nitrogen.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application Nos. 61/659,541, filed on Jun. 14, 2012, and 61/810,339, filed on Apr. 10, 2013, the entire contents of both of which are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

In various aspects, the invention is related to low emission power production with separation and/or capture of resulting emissions.

BACKGROUND OF THE INVENTION

Capture of gases emitted from power plants is an area of increasing interest. Power plants based on the combustion of petroleum products generate carbon dioxide as a by-product of the reaction. Historically this carbon dioxide has been released into the atmosphere after combustion. However, it is becoming increasingly desirable to identify ways to find alternative uses for the carbon dioxide generated during combustion.

Combined cycle power plants provide an efficient way to generate electricity from the burning of petroleum products or other carbon-based fuels. Combined cycle power plants can leverage an initial combustion reaction to power multiple turbines for generation of electricity, leading to more efficient power generation. However, conventional methods for capturing carbon dioxide tend to reduce the efficiency of electricity generation, due to the additional energy required to capture and/or sequester the carbon dioxide.

PCT International Publication No. WO/2012/003079 describes systems and methods for generating electricity using a combined cycle power plant based on combustion of carbon-based fuels. The systems and methods include use of stoichiometric ratios of fuels to oxygen in the combustion reaction as well as recycling of combustion exhaust gas as part of the input to the combustion reaction. The combustion products are withdrawn from the system as a purge gas stream. The CO 2 in the purge gas stream is removed, for example, using a solvent such as potassium carbonate.

U.S. Pat. No. 6,902,602 describes methods for performing separations by swing adsorption where it is desirable to minimize or avoid interaction between one of the components in a gas stream being separated and a component of the gas stream used for purging the swing adsorption apparatus. Separations of hydrogen and carbon dioxide from syngas stream are noted as an example, where it is desirable to avoid contamination of the hydrogen product stream with any oxygen from the typical oxygen-containing purge stream. The separation methods include use of one or more buffer gas steps during a separation, where a buffer different from any other components is used to prevent contamination between steps of a separation process.

U.S. Published Patent Application No. 2012/0125194 describes an autothermal cycle for CO 2 capture. A combustion exhaust gas is contacted with an adsorbent bed to adsorb CO 2 . The CO 2 is then removed by contacting the adsorbent with a gas comprising steam. The resulting output gas containing steam and CO 2 is conveyed to a vapor recompression system to recover H 2 O, CO 2 , and heat. The recovered H 2 O and heat are then used to provide steam for the sweep gas. The amount of steam sweep gas required for recovery of CO 2 is described as being Ë1 mole of steam per mole of input feed gas. The flue gas input feeds are described as having a CO 2 content of 15 mol % or less. Thus, the steam/CO 2 molar ratio is described as being at least Ë6 moles of steam per mole of CO 2 . The process is described as recovering at least 90% of the carbon in the combustion exhaust gas as part of the output gas.

Other potentially relevant publications can include U.S. Patent Application Publication No. 20120318533, European Patent Application No. EP 2220338, an article by Reijers et al., Ind. Eng. Chem. Res., 2009, 48, 6966, and an article by Wright et al., Energy Procedia, 2011, 4, 1457, inter alia.

SUMMARY OF THE INVENTION

One aspect of the present invention relates to a method for generating power, comprising: compressing a recycled exhaust gas in a main compressor to generate a compressed recycle exhaust gas, the compressed recycle exhaust gas having a recycle temperature from about 400Â° C. to about 500Â° C. and a recycle pressure from about 10 bara (about 1.0 MPaa) to about 30 bara (about 3.0 MPaa), the recycled exhaust gas comprising at least about 70 vol % of N 2 and at least about 10 vol % of CO 2 ; compressing enriched air in an inlet compressor to generate a compressed oxidant; passing a first portion of the compressed recycle exhaust gas into a combustion chamber; stoichiometrically combusting the compressed oxidant and a fuel in a combustion chamber and in the presence of the first portion of the compressed recycle exhaust gas, thereby generating a discharge stream, wherein the first portion of the compressed recycle exhaust gas acts as a diluent configured to moderate the temperature of the discharge stream; expanding the discharge stream in an expander to at least partially drive the main compressor and generate the recycled exhaust gas; passing a second portion of the recycled exhaust gas into a swing adsorption reactor comprising an adsorbent material; adsorbing CO 2 on the adsorbent material at an adsorption temperature that differs from the recycle temperature by less than about 20Â° C. and at an adsorption pressure that differs from the recycle pressure by less than about 1 bar (about 0.1 MPa); recovering an N 2 stream with a purity of at least about 95 vol % from a forward end of the reactor, the recovered N 2 stream having a pressure that differs from the separation pressure by less than about 0.5 bar (about 50 kPa); reducing the pressure in the swing adsorption reactor to a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) by outputting a blow down stream from at least one end of the reactor; and purging the swing adsorption reactor with a steam purge at a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) to generate a CO 2 recovery stream, the CO 2 recovery stream comprising at least about 90% of the CO 2 present in the second portion of the recycled exhaust gas, the steam purge containing less than 1.0 moles (e.g., less than about 0.8 moles) of H 2 O per mole of CO 2 in the second portion of the recycled exhaust gas.

Another aspect of the present invention relates to a method for production of N 2 and CO 2 from a reactor exhaust stream, comprising: passing a reactor exhaust stream comprising at least about 70 vol % N 2 and at least about 10 vol % CO 2 into a swing adsorption reactor comprising an adsorbent material, the reactor exhaust stream having a pressure between about 10 bara (about 1.0 MPaa) to about 30 bara (about 3.0 MPaa); adsorbing CO 2 on the adsorbent material at an adsorption temperature of at least 400Â° C.; recovering an N 2 stream with a purity of at least about 95 vol % from a forward end of the reactor, the recovered N 2 stream having a pressure that differs from the pressure of the reactor exhaust stream by about 0.5 bar (about 50 kPa) or less; reducing the pressure in the swing adsorption reactor to a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) by outputting a blow down stream from at least one end of the reactor; and purging the swing adsorption reactor with a steam purge at a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) to generate a CO 2 recovery stream, the CO 2 recovery stream comprising at least about 90% of the CO 2 present in the reactor exhaust stream, the steam purge containing less than about 1.0 moles (e.g., less than about 0.8 moles) of H 2 O per mole of CO 2 in the reactor exhaust stream.

Yet another aspect of the present invention relates to a method for production of N 2 and CO 2 from a reactor exhaust stream, comprising: compressing a recycled exhaust gas to generate a compressed recycle exhaust gas, the compressed recycle exhaust gas having a recycle temperature from about 400Â° C. to about 500Â° C. and a recycle pressure from about 10 bara (about 1.0 MPaa) to about 30 bara (about 3.0 MPaa), the recycled exhaust gas comprising at least about 70 vol % of N 2 and at least about 10 vol % of CO 2 ; separating CO 2 from N 2 in at least a portion of the compressed recycle exhaust gas in a cyclical pressure swing adsorption process, a process cycle comprising: passing the at least a portion of the compressed recycle exhaust gas into a swing adsorption reactor comprising an adsorbent material, the reactor exhaust stream having a pressure between about 10 bara (about 1.0 MPaa) to about 30 bara (about 3.0 MPaa); adsorbing CO 2 on the adsorbent material at an adsorption temperature that differs from the recycle temperature by less than about 20Â° C. and at an adsorption pressure that differs from the recycle pressure by less than about 1 bar (0.1 MPa); recovering an N 2 stream with a purity of at least about 95 vol % from a forward end of the reactor, the recovered N 2 stream having a pressure that differs from the pressure of the reactor exhaust stream by about 0.5 bar (about 50 kPa) or less, the recovered N 2 stream having a temperature that differs from the recycle temperature by 20Â° C. or less; reducing the pressure in the swing adsorption reactor to a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) by outputting a blow down stream from at least one end of the reactor; and purging the swing adsorption reactor with a steam purge at a pressure from about 1.0 bara (about 0.1 MPaa) to about 3.0 bara (about 0.3 MPaa) to generate a CO 2 recovery stream, the CO 2 recovery stream comprising at least about 90% of the CO 2 present in the reactor exhaust stream, the steam purge containing less than about 1.0 moles (e.g., less than about 0.8 moles) of H 2 O per mole of CO 2 in the reactor exhaust stream; and separating the CO 2 recovery stream into a CO 2 product stream and water, the CO 2 product stream containing at least about 90 vol % of CO 2 , wherein the at least a portion of the compressed recycle exhaust gas and the steam purge comprise at least about 95 vol % of the gases introduced into the swing adsorption reactor during a process cycle.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 schematically shows an example of a combined cycle system for generating electricity based on combustion of a carbon-based fuel.

FIG. 2 schematically shows a configuration for a pressure swing adsorption process.

FIG. 3 shows a graph of CO 2 purity versus steam purge content for Example 4.

FIG. 4 pictorially shows the cycle setup of a 3-vessel sorptive arrangement without interconnection between vessels.

FIG. 5 pictorially shows the cycle setup of a 4-vessel sorptive arrangement without interconnection between vessels.

FIG. 6 pictorially shows the cycle setup of a 4-vessel sorptive arrangement with some level of interconnection between vessels.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In various aspects, systems and methods are provided for power generation using turbines while reducing and/or mitigating emissions during power generation. In a combined cycle generation system, the flue gas from a combustion reaction for a gas turbine can also be used to power a steam turbine. The flue gas can then be recycled for use as part of the input to the gas turbine. A portion of the recycled exhaust gas can be effectively separated to generate a high purity carbon dioxide stream, while reducing and/or minimizing the energy required for the separation, and without needing to reduce the temperature of the flue gas. This can allow another (e.g., the remaining) portion of the recycled exhaust gas, which can typically be composed of a majority of nitrogen, to be used to generate additional electricity, e.g., without having to adjust the pressure and/or temperature of the recycled exhaust gas to accommodate the conditions required for the carbon dioxide separation process. Thus, improved energy recovery can be realized from the combined cycle system, while also generating relatively high purity streams of carbon dioxide and nitrogen.

A variety of system configuration and processing conditions can contribute to power generation with low emissions that can also be effectively separated and/or captured for further use. For example, the input gas flow for the combustor to the gas turbine can be selected to have a desirable composition, e.g., a roughly stoichiometric ratio of fuel to oxygen. Having a roughly stoichiometric ratio of fuel to oxygen can reduce the amount of unreacted oxygen present in the gas output after combustion. This can facilitate separation of the other combustion products, as well as potentially reducing/eliminating the production of NO x species. More generally, a roughly stoichiometric combustion reaction with a desirable feed can result in an exhaust primarily composed of CO 2 , N 2 , and H 2 O.

Another example of a system configuration and/or process condition that can contribute to power generation with low emission that can be effectively separated and/or captured can include using recycled exhaust gas as part of the input gas flow. The gas flow exiting the combustion process can advantageously be used to power a gas turbine. After powering the gas turbine, this gas flow corresponds to an exhaust gas. This exhaust gas can be used in a combined cycle configuration power a steam turbine by using a heat exchanger to extract heat from the exhaust gas. This exhaust gas can then be recycled, after removal of water, for use as part of the input gas flow. The exhaust gas can advantageously have an elevated volume percentage of CO 2 relative to ambient air, which can also assist in selecting the CO 2 content of the input gas flow to the combustion reaction. Controlling the amount of CO 2 in the combustion products can be beneficial for enhancing the energy output captured from the combustion reaction.

Recycling all of the exhaust gas can allow for all of the carbon in the exhaust to be maintained in a single stream until the stream can be diverted to a carbon capture process. Typically, though, less than all of the recycled exhaust gas may be needed to provide additional gas for the input gas flow to combustion. As a result, any excess exhaust gas can be diverted, e.g., for separation into high purity CO 2 and N 2 gas streams. A convenient location in the process to perform this diversion can be after the recycled exhaust gas has been modified to achieve the temperature and pressure desired for the input gas flow to combustion. At this point, it can be desirable to perform the separation of CO 2 and N 2 while reducing/minimizing the amount of energy lost due to temperature/pressure reductions. For example, typical solvent methods for separating CO 2 and N 2 require a reduction in the temperature of the recycled exhaust gas. For such conventional solvent methods, in order to preserve as much energy in the N 2 stream as possible, heat exchangers can be used to transfer heat from the recycled exhaust gas to the separated N 2 stream.

In some aspects, the separation of CO 2 and N 2 can be performed by using a pressure swing adsorption (PSA) process to separate the CO 2 and N 2 at the temperature and pressure of the input gas flow to the combustion reaction. Using pressure swing adsorption to perform the separation can allow for recovery, for example, of at least about 60% (such as at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 97%, at least about 98%, at least about 99%, at least about 99.3%, or at least about 99.5%) of the CO 2 in the recycled exhaust gas, e.g., while also generating an N 2 stream with at least about 90% purity (such as at least about 93% purity, at least about 95% purity, at least about 97% purity, at least about 98% purity, or at least about 99% purity) and/or a CO 2 stream with at least about 80% purity (such as at least about 85% purity, at least about 90% purity, at least about 95% purity, at least about 97% purity, at least about 98% purity, at least abo

CROSS-REFERENCE TO RELATED APPLICATIONS

FIELD OF THE INVENTION

In various aspects, the invention is related to low emission power production with separation and/or capture of resulting emissions.

BACKGROUND OF THE INVENTION

SUMMARY OF THE INVENTION

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 schematically shows an example of a combined cycle system for generating electricity based on combustion of a carbon-based fuel.

FIG. 2 schematically shows a configuration for a pressure swing adsorption process.

FIG. 3 shows a graph of CO 2 purity versus steam purge content for Example 4.

FIG. 4 pictorially shows the cycle setup of a 3-vessel sorptive arrangement without interconnection between vessels.

FIG. 5 pictorially shows the cycle setup of a 4-vessel sorptive arrangement without interconnection between vessels.

FIG. 6 pictorially shows the cycle setup of a 4-vessel sorptive arrangement with some level of interconnection between vessels.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In various aspects, the operating conditions for a PSA reactor can be selected to facilitate the power generation process while still effectively capturing the exhaust gases. Using a relatively high temperature PSA can preserve the energy content of the N 2 portion of the recycled exhaust gas, so that the N 2 gas stream can be used to power an additional turbine for electricity generation. By contrast, a conventional separation method for CO 2 separation such as solvent separation can typically require adjustment of the temperature and/or pressure of the stream to facilitate the separation. Thus, instead of requiring energy to modify the recycled exhaust prior to treating the exhaust gases, use of a PSA reactor can allow the capture process to be adjusted to match the operating conditions for power generation.

The high temperature PSA can also be performed using a process cycle avoiding the need for high temperature steam and/or another energy intensive purge gas. This can allow high purity CO 2 to be recovered while reducing/minimizing the amount of energy lost to capture of the exhaust gases.

Combined Cycle Process for Power Generation with Low Emissions

In various aspects, systems and methods are provided for generating power while controlling and/or capturing the emissions produced during power generation. One goal of power generation is to use input feeds (such as fuels) as efficiently as possible, so that power generation can be increased/optimized for a given amount of fuel and/or of equipment. Based on the conditions for effective power generation, a goal for control/capture of emissions can be to provide effective capture of emissions while reducing/minimizing the changes to the conditions for power generation.

As used herein, the term âstoichiometric combustionâ refers to a combustion reaction having a volume of reactants comprising a fuel and an oxidizer and a volume of products formed by combusting the reactants, where substantially the entire volume of the reactants is used to form the products. As used herein, the term âsubstantially stoichiometric combustionâ refers to a combustion reaction having a molar ratio of combustion fuel to oxygen ranging from plus to minus about 10%, e.g., from about plus to minus about 5%, of the oxygen required for a stoichiometric ratio. For example, the stoichiometric ratio of fuel to oxygen for methane is 1:2 (CH 4 +2O 2

CO 2 +2H 2 O), whereas propane should have a stoichiometric ratio of fuel to oxygen of 1:5. Another way of measuring substantially stoichiometric combustion can be as a ratio of oxygen supplied to oxygen required for stoichiometric combustion, e.g., from about 0.9:1 to about 1.1:1 or from about 0.95:1 to about 1.05:1.

In some aspects, the processes described herein can be used to produce ultra low emission electric power and CO 2 for enhanced oil recovery (EOR), enhanced hydrocarbon recovery (EHR), and/or sequestration/capture applications; in such cases, the process conditions for EOR/EHR may be similar to sequestration/capture application or may be slightly different. In one or more aspects, a mixture of oxygen-enriched gas (e.g., enriched air) and fuel can be stoichiometrically or substantially stoichiometrically combusted and simultaneously mixed with a stream of recycled exhaust gas. The stream of recycled exhaust gas, generally including products of combustion such as CO 2 , can be used as a diluent to control, adjust, and/or otherwise moderate the temperature of combustion and the exhaust that enters the succeeding expander. As a result of using oxygen enrichment, the recycled exhaust gas can have an increased CO 2 content, thereby allowing the expander to operate at even higher expansion ratios for the same inlet and discharge temperatures, thereby producing significantly increased power.

Combustion in commercial gas turbines at stoichiometric conditions or substantially stoichiometric conditions (e.g., âslightly richâ combustion) can prove advantageous to eliminate the cost of excess oxygen removal. By cooling the exhaust and condensing the water out of the cooled exhaust stream, a relatively high content CO 2 exhaust stream can be produced. While a portion of the recycled exhaust gas can be utilized for temperature moderation in a closed Brayton cycle, a remaining purge stream can be used for EOR and/or enhanced hydrocarbon recovery applications and/or electric power can be produced with little or no sulfur oxides (SO x ), nitrogen oxides (NO x ), and/or CO 2 being emitted to the atmosphere. The result of this process can include the production of power in three separate cycles and the manufacturing of additional CO 2 . In some aspects, performing stoichiometric combustion can allow for generation of an exhaust stream consisting substantially of CO 2 , H 2 O, and N 2 . An exhaust stream consisting substantially of CO 2 , H 2 O, and N 2 is defined as an exhaust stream that contains about 5 mol % or less of other gas molecules, e.g., about 2.5 mol % or less or about 1 mol % or less.

FIG. 1 depicts a schematic of an illustrative integrated system 100 for power generation and CO 2 recovery using a combined-cycle arrangement, according to one or more embodiments. In at least one embodiment, the power generation system 100 can include a gas turbine system 102 characterized as a power-producing, closed Brayton cycle. The gas turbine system 102 can have a first or main compressor 104 coupled to an expander 106 via a shaft 108 . The shaft 108 can be any mechanical, electrical, and/or other power coupling, thereby allowing a portion of the mechanical energy generated by the expander 106 to drive the main compressor 104 . In at least one embodiment, the gas turbine system 102 can be a standard gas turbine, where the main compressor 104 and expander 106 form the compressor and expander ends, respectively. In other embodiments, however, the main compressor 104 and expander 106 can be individualized components in the system 102 .

The gas turbine system 102 can also include a combustion chamber 110 configured to combust a fuel introduced via line 112 mixed with an oxidant introduced via line 114 . In one or more embodiments, the fuel in line 112 can include any suitable hydrocarbon gas or liquid, such as natural gas, methane, ethane, naphtha, butane, propane, syngas, diesel, kerosene, aviation fuel, coal derived fuel, bio-fuel, oxygenated hydrocarbon feedstock, or any combinations thereof. The oxidant via line 114 can be derived from a second or inlet compressor 118 fluidly coupled to the combustion chamber 110 and adapted to compress a feed oxidant introduced via line 120 . In one or more embodiments, the feed oxidant in line 120 can include atmospheric air, enriched air, or combinations thereof. When the oxidant in line 114 includes a mixture of atmospheric air and enriched air, the enriched air can be compressed by the inlet compressor 118 before and/or after being mixed with the atmospheric air. The enriched air can have an overall oxygen concentration of at least about 30 vol %, e.g., at least about 35 vol %, at least about 40 vol %, at least about 45 vol %, at least about 50 vol %, from about 30 vol % to about 70 vol %, from about 30 vol % to about 65 vol %, from about 30 vol % to about 60 vol %, from about 30 vol % to about 55 vol %, from about 30 vol % to about 50 vol %, from about 35 vol % to about 70 vol %, from about 35 vol % to about 65 vol %, from about 35 vol % to about 60 vol %, from about 35 vol % to about 55 vol %, from about 35 vol % to about 50 vol %, from about 40 vol % to about 70 vol %, from about 40 vol % to about 65 vol %, from about 40 vol % to about 60 vol %, from about 40 vol % to about 55 vol %, from about 40 vol % to about 50 vol %, from about 45 vol % to about 70 vol %, from about 45 vol % to about 65 vol %, from about 45 vol % to about 60 vol %, from about 45 vol % to about 55 vol %, from about 45 vol % to about 50 vol %, from about 50 vol % to about 70 vol %, from about 50 vol % to about 65 vol %, or from about 50 vol % to about 60 vol %.

The enriched air can be derived from any one or more of several sources, including implementing various technologies upstream of the inlet compressor 118 to produce the enriched air. For example, the enriched air can be derived from such separation technologies as membrane separation, pressure swing adsorption, temperature swing adsorption, nitrogen plant-byproduct streams, and/or combinations thereof. The enriched air can additionally or alternately be derived from an air separation unit (ASU), such as a cryogenic ASU, for producing nitrogen for pressure maintenance or other purposes. The reject stream from the ASU can be rich in oxygen, e.g., having an overall oxygen content from about 50 vol % to about 70 vol %. This reject stream can be used as at least a portion of the enriched air and subsequently diluted, if needed, with unprocessed atmospheric air to obtain the desired oxygen concentration for the application.

As will be described in more detail below, the combustion chamber 110 can also receive a compressed recycle exhaust gas in line 144 , including an exhaust gas recirculation primarily having CO 2 and nitrogen components. The compressed recycle exhaust gas in line 144 can be derived from the main compressor 104 and adapted to help facilitate a stoichiometric or substantially stoichiometric combustion of the compressed oxidant in line 114 and fuel in line 112 by moderating the temperature of the combustion products. As can be appreciated, recirculating the exhaust gas can serve to increase the CO 2 concentration in the exhaust gas.

An exhaust gas in line 116 directed to the inlet of the expander 106 can be generated as a product of combustion of the fuel in line 112 and the compressed oxidant in line 114 , in the presence of the compressed recycle exhaust gas in line 144 . In at least one embodiment, the fuel in line 112 can be primarily natural gas, thereby generating a discharge or exhaust gas via line 116 that can include volumetric portions of vaporized water, CO 2 , nitrogen, nitrogen oxides (NO x ), and sulfur oxides (SO x ). In some embodiments, a small portion of unburned fuel in line 112 or other compounds can also be present in the exhaust gas in line 116 due to combustion equilibrium limitations. As the exhaust gas in line 116 expands through the expander 106 , it can generate mechanical power to drive the main compressor 104 , an electrical generator, and/or other facilities, and can also produce a gaseous exhaust in line 122 having a heightened CO 2 content resulting from the influx of the compressed recycle exhaust gas in line 144 . In some implementations, the expander 106 may be adapted to produce additional mechanical power that may be used for other purposes.

Additionally or alternately, the power generation system 100 can include an exhaust gas recirculation (EGR) system 124 , which can include a heat recovery steam generator (HRSG) 126 , or similar device, fluidly coupled to a steam gas turbine 128 . In at least one embodiment, the combination of the HRSG 126 and the steam gas turbine 128 can be characterized as a power-producing closed Rankine cycle. In combination with the gas turbine system 102 , the HRSG 126 and the steam gas turbine 128 can form part of a combined-cycle power generating plant, such as a natural gas combined-cycle (NGCC) plant. The gaseous exhaust in line 122 can be introduced to the HRSG 126 in order to generate steam via line 130 and a cooled exhaust gas in line 132 . Additionally or alternately, the steam in line 130 can be sent to the steam gas turbine 128 to generate additional electrical power.

The cooled exhaust gas in line 132 can be sent to a first cooling unit 134 adapted to cool the cooled exhaust gas in line 132 and generate a cooled recycle gas stream 140 . The first cooling unit 134 can include, for example, one or more contact coolers, trim coolers, evaporative cooling unit, or any combination thereof. The first cooling unit 134 can additionally or alternately be adapted to remove a portion of any condensed water from the cooled exhaust gas in line 132 via a water dropout stream 138 . In at least one embodiment, the water dropout stream 138 may be routed to the HRSG 126 via line 141 to provide a water source for the generation of additional steam in line 130 therein. Additionally or alternately, the water recovered via the water dropout stream 138 can be used for other downstream applications, such as supplementary heat exchanging processes.

In most embodiments, the cooled recycle gas stream 140 can be directed to a boost compressor 142 . Cooling the cooled exhaust gas in line 132 in the first cooling unit 134 can reduce the power required to compress the cooled recycle gas stream 140 in the boost compressor 142 . As opposed to a conventional fan or blower system, the boost compressor 142 can be configured to compress, and thus increase, the overall density of the cooled recycle gas stream 140 , thereby directing a pressurized recycle gas in line 145 downstream, where the pressurized recycle gas in line 145 can thus exhibit an increased mass flow rate for the same volumetric flow. This can prove advantageous, since the main compressor 104 can be volume-flow limited, and directing more mass flow through the main compressor 104 can result in higher discharge pressures, thereby translating into higher pressure ratios across the expander 106 . Higher pressure ratios generated across the expander 106 can allow for higher inlet temperatures and, therefore, an increase in expander 106 power and/or efficiency. As can be appreciated, this may prove advantageous, since the CO 2 -rich exhaust gas in line 116 can generally maintain a higher specific heat capacity.

Since the suction pressure of the main compressor 104 can typically be a function of its suction temperature, a cooler suction temperature can generally demand less power to operate the main compressor 104 for the same mass flow. Consequently, the pressurized recycle gas in line 145 can optionally be directed to a second cooling unit 136 , e.g., which can include one or more direct contact coolers, trim coolers, evaporative cooling units, or any combination thereof. In at least one embodiment, the second cooling unit 136 can serve as an aftercooler adapted to remove at least a portion of the heat of compression generated by the boost compressor 142 on the pressurized recycle gas in line 145 . The second cooling unit 136 can additionally or alternately extract additional condensed water via a water dropout stream 143 . In some such embodiments, the water dropout streams 138 , 143 can converge into stream 141 and may or may not be routed to the HRSG 126 to generate additional steam via line 130 therein. While only first and second cooling units

134 , 136 are depicted herein, any desired number of cooling units can be employed to suit a variety of applications, without departing from the scope of the disclosure.

The main compressor 104 can be configured to receive and compress the pressurized recycle gas in line 145 to a pressure nominally at or above the pressure of the combustion chamber 110 , thereby generating the compressed recycle exhaust gas in line 144 . As can be appreciated, cooling the pressurized recycle gas in line 145 in the second cooling unit 136 after compression in the boost compressor 142 can allow for an increased volumetric mass flow of exhaust gas into the main compressor 104 . Consequently, this can reduce the amount of power required to compress the pressurized recycle gas in line 145 to a predetermined pressure.

In many embodiments, a purge stream 146 can be recovered from the compressed recycle exhaust gas in line 144 and subsequently treated in a CO 2 separator 148 to capture CO 2 at an elevated pressure via line 150 . Preferably, the CO 2 separator can be a pressure swing adsorption unit, as described in further detail below. The separated CO 2 in line 150 can be used for sales, used in another processes requiring CO 2 , and/or further compressed and injected into a terrestrial reservoir for enhanced oil recovery (EOR), enhanced hydrocarbon recovery (EHR), sequestration, or another purpose. Because of the stoichiometric or substantially stoichiometric combustion of the fuel in line 112 combined with a boosted pressure from the boost compressor 142 , the CO 2 partial pressure in the purge stream 146 can be much higher than in conventional gas turbine exhausts.

A residual stream 151 , essentially depleted of CO 2 and consisting primarily of nitrogen, can additionally or alternately be derived from the CO 2 separator 148 . In some embodiments, the residual stream 151 can be introduced to a gas expander 152 to provide power and an expanded depressurized gas, or exhaust gas, via line 156 . The expander 152 can be, for example, a power-producing nitrogen expander. As depicted, the gas expander 152 can be optionally coupled to the inlet compressor 118 through a common shaft 154 or other mechanical, electrical, or other power coupling, thereby allowing a portion of the power generated by the gas expander 152 to drive the inlet compressor 118 . However, during startup of the <

CLAIMS

Claims ( 18 )

What is claimed is:

1. A method for generating power, comprising:

compressing a recycled exhaust gas in a main compressor to generate a compressed recycle exhaust gas, the compressed recycle exhaust gas having a recycle temperature from about 400Â° C. to about 500Â° C. and a recycle pressure from about 10 bara (about 1.0 MPaa) to about 30 bara (about 3.0 MPaa), the recycled exhaust gas comprising at least about 70 vol % of N 2 and at least about 10 vol % of CO 2 ;

compressing atmospheric air, enriched air, or mixtures thereof in an inlet compressor to generate a compressed oxidant;

passing a first portion of the compressed recycle exhaust gas into a combustion chamber;

substantially stoichiometrically combusting the compressed oxidant and a fuel in the combustion chamber and in the presence of the first portion of the compressed recycle exhaust gas, thereby generating a discharge stream, wherein the first portion of the compressed recycle exhaust gas acts as a diluent configured to moderate a temperature of the discharge stream;

expanding the discharge stream in an expander to at least partially drive the main compressor and generate the recycled exhaust gas;

passing a second portion of the compressed recycle exhaust gas into a swing adsorption reactor comprising an adsorbent material;

adsorbing CO 2 on the adsorbent material at an adsorption temperature that differs from the recycle temperature by less than about 20Â° C. and at an adsorption pressure that differs from the recycle pressure by less than about 1 bar (about 0.1 MPa);

recovering an N 2 stream with a purity of at least about 95 vol % from a forward end of the swing adsorption reactor, the recovered N 2 stream having a pressure that differs from a separation pressure by less than about 0.5 bar (about 50 kPa);

reducing a pressure in the swing adsorption reactor to a pressure from about 1.0 bara (about 0.1 MPaa) to about 4.0 bara (about 0.4 MPaa) by outputting a blow down stream from at least one end of the swing adsorption reactor; and

purging the swing adsorption reactor with a steam purge at a pressure from about 1.0 bara (about 0.1 MPaa) to about 4.0 bara (about 0.4 MPaa) to generate a CO 2 recovery stream, the CO 2 recovery stream comprising at least about 90% of the CO 2 present in the second portion of the compressed recycle exhaust gas; the steam purge containing less than 1.0 mole of H 2 O per mole of CO 2 in the second portion of the compressed recycle exhaust gas.

2. The method of claim 1 , wherein the passing the second portion of the compressed recycle exhaust gas, the adsorbing, the recovering, the reducing, and the purging comprise a pressure swing adsorption cycle, the second portion of the compressed recycle exhaust gas and the steam purge comprising at least about 95 vol % of gases introduced into the swing adsorption reactor during the pressure swing adsorption cycle.

3. The method of claim 1 , further comprising passing a second purge stream through the swing adsorption reactor to generate a second CO 2 recovery stream, the second purge stream having a different composition than the steam purge.

4. The method of claim 3 , wherein the passing the second portion of the compressed recycle exhaust gas, the adsorbing, the recovering, the reducing, and the purging comprise a pressure swing adsorption cycle, the second portion of the compressed recycle exhaust gas, the steam purge, and the second purge stream comprising at least about 95 vol % of the gases introduced into the swing adsorption reactor during the pressure swing adsorption cycle.

5. The method of claim 1 , further comprising separating the CO 2 recovery stream into a CO 2 product stream and water, the CO 2 product stream containing at least about 90 vol % of CO 2 .

6. The method of claim 5 , wherein the CO 2 product stream further comprises N 2 .

7. The method of claim 1 , wherein the compressed oxidant has an oxygen concentration between about 30 vol % and about 50 vol %.

8. The method of claim 1 , wherein the recycled exhaust gas has a CO 2 concentration between about 10 vol % and about 20 vol %.

9. The method of claim 1 , wherein the recycled exhaust gas has an O 2 concentration of about 1 vol % or less.

10. The method of claim 1 , wherein the adsorbent comprises an alkali metal carbonate and an oxide of an alkaline earth metal or a transition metal.

11. The method of claim 10 , wherein the alkali metal carbonate is potassium carbonate, lithium carbonate, or sodium carbonate.

12. The method of claim 10 , wherein the adsorbent comprises a transition metal oxide of the transition metal that forms the oxide with the transition metal in a +2 or +3 oxidation state.

13. The method of claim 10 , wherein the adsorbent comprises at least one of lithium carbonate and potassium carbonate and at least one of lanthanum oxide, yttrium oxide, and magnesium oxide.

14. The method of claim 1 , wherein the adsorbent comprises an alkaline earth metal carbonate and an oxide of a transition metal.

15. The method of claim 14 , wherein the alkaline earth metal carbonate is magnesium carbonate or calcium carbonate.

16. The method of claim 14 , wherein the adsorbent comprises a transition metal oxide of the transition metal that forms the oxide with the transition metal in a +2 or +3 oxidation state.

17. The method of claim 14 , wherein the adsorbent comprises at least one of magnesium carbonate and calcium carbonate and at least one of lanthanum oxide, yttrium oxide, and magnesium oxide.

18. The method of claim 1 , wherein the temperature of the recovered N 2 stream is at least the adsorption temperature.

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