Hybrid Membrane Based Systems for CO 2 Capture on Natural Gas and Coal Power Plants

Stanbridge Capital Oil & Energy Hybrid Membrane Based Systems for CO 2 Capture on Natural Gas and Coal Power Plants PCCC2, Bergen, 18 th September 2013 Bouchra Belaissaoui, Eric Favre LRGP, Nancy, France Yann Le Moullec EDF R&D, Chatou, France Gilles Cabot CORIA, Rouen, France David Willson Stanbridge Capital, New York, USA 1

Post-combustion carbon capture and storage (CCS) technology Post-combustion CO 2 capture Challenge: Reduction of the energy requirement of the capture step Flue gas CO 2 content : 4-30% Separation unit CO 2 capture Capture ratio >=90% CO 2 to transport CO 2 purity >=90% Reference (MEA absorption + compression) : 4 GJ/ton of recovered CO 2 Target : 2.5GJ/tonofrecoveredCO of 2 Alternative approaches : Membrane based hybrid processes? 2

Outline 1- Membrane process specification 2. Hybrid process I: Coal power plant 3. Hybrid process II: Natural gas turbine 4. Conclusion and perspectives 3

Post-combustion 1- Membrane unit process carbon capture and storage (CCS) technology Feed Flue gas Upstream P CO 2 N 2 Retentate CO 2 /N 2 Downstream P Permeable & CO 2 selective membrane material Permeate CO 2 rich stream 2 CO 2 and N 2 are separated due to their different permeability in the membrane material The driving force is ensured by an appropriate transmembrane pressure CO 2 permeates faster than N 2 CO 2 rich ihstream is recovered inthe permeate 4

1- Membrane process simulation Feed : Q in x in P in Upstream Downstream P P CO 2 N 2 Retentate : Q out = (1- ).Q in x out Permeate : Q p =.Q in, y Modeling : Cross-plug flow model* Operating parameter Performance parameters Material properties - Pressure ratio: =P /P - Inlet CO 2 content, xin -CO 2 permeate purity, y Energy requirement -CO 2 recovery ratio, R + - Membrane selectivity: α= CO2 / N2 -CO 2 permeability: CO2 Membrane surface area * Bounaceur R. et al, (2006) Energy, 31, 2556-2570. 5

Membranes and post-combustion CCS: A tentative process selection map 4.0 3.5 Standard MEA absorption process red CO 2 ) E (GJ/to on of recove Plac ce of memb ranes in CCS st trategy 3.0 2.5 2.0 1.5 1.0 0.5 Natural gas turbine Coal combustion Steel industry U.E target : E=< 2+0.5 (compression to 110 bar)gjth/ton CO 2 =100 00 0.0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 Hybrid process? Multistage memb. Key : There is a substantial benefit from Hybrid process : Membrane as a strategically increasing the inlet CO 2 content preconcentration unit Biogas Biogas combustion Inlet CO 2 mole fraction (x in ) Single stage membrane process E < 2.5 GJ/ton Membrane as a polishing unit R = 0.9 y = 0.9 B. Belaissaoui, D. Willson, E. Favre, Chemical Engineering Journal, 211 212 (2012) 122 132 6

Outline 1- Membrane process specification 2. Hybrid process I: Coal power plant 3. Hybrid process II: Natural gas turbine 4. Conclusion and perspectives 7

2- Hybrid process: Membrane preconcentration + cryogeny Q in Retentate T=30 C P in =1bar x in, CO2 Membrane unit Q x CO2 P =1bar Cryogenic unit Incondensable Q out x out >98% P out =110bar CO 2 capture ratio >90% B. Belaissaoui, Y. Le Moullec, D. Willson, E. Favre, Journal of Membrane Science, 415-416 (2012) 424-434 8

2- Hybrid process: Membrane preconcentration + cryogeny Q in T=30 C Membrane unit Retentate Q x CO2 Cryogenic yg unit P in =1bar P =1bar x out >98% x in, CO2 P out =110bar Incondensable Q out Three-stage compression with intercoolers (Aspen software) with coupled turbine & booster compressor * B. Belaissaoui, Y. Le Moullec, D. Willson, E. Favre, Journal of Membrane Science, 415-416 (2012) 424-434 9

1- Hybrid process: Membrane preconcentration + cryogeny Q in T=30 C P in =1bar x in, CO2 Retentate Membrane unit Optimisation variable Q x CO2 P =1bar Cryogenic unit Q out x out >98% P out =110bar Incondensable Occurrence of a minimum overall energy requirement? * B. Belaissaoui, Y. Le Moullec, D. Willson, E. Favre, Journal of Membrane Science, 415-416 (2012) 424-434 10

Simulation results 10 E (GJ/ton of recovered CO 2 ) Feed compression with ERS CO 2 /N 2 =50 x in =0.15 1 0.375 0.425 0.475 0.525 0.575 0.625 0.675 0.725 0.775 Intermediate CO 2 mole fraction (x') E-Membrane decreases significantly when a moderate CO 2 permeate purity is aimed 11

Simulation results 10 d CO 2 ) of recovered E (GJ/ton o 1 0.375 0.425 0.475 0.525 0.575 0.625 0.675 0.725 0.775 Intermediate CO 2 mole fraction (x') E-Cryogeny decreases significantly ifi when concentrated CO 2 flue gase is treated 12

Simulation results 10 EHybrid= E Membrane +E Cryogeny E (GJ/ton of recovered CO 2 ) 1 0.375 0.425 0.475 0.525 0.575 0.625 0.675 0.725 0.775 Intermediate CO 2 mole fraction (x') Occurrence of a minimum energy requirement towards x 13

Simulation results 10 E (GJ/ton of recovered CO 2 ) All Cryogeny Standard d MEA absorption+compression i 20% energy decrease x in =0.15 CO 2 /N 2 =50 1 0.375 0.425 0.475 0.525 0.575 0.625 0.675 0.725 0.775 Intermediate CO 2 mole fraction (x') The hybrid process significantly decreases the energy requirement compared to the standalone cryogenic separation and MEA absorption B. Belaissaoui, Y. Le Moullec, D. Willson, E. Favre, Journal of Membrane Science, 415 416 (2012) 424 434 14

Outline 1- Membrane process specification 2. Hybrid process I: Coal power plant 3. Hybrid process II: Natural gas turbine 4. Conclusion and perspectives 15

3- Integrated membrane / gas turbine process Proposed concept : Flue gas recirculation + combustion in oxygen enhanced air (OEA) Natural gas Power Gas Separation unit 1 Separation unit 2 turbine O 2 /N 2 OEA CO 2 capture cycle Oxycombustion (100%O 2 ) Moderate O 2 enrichment FGR # [O 2 ] : 40-80% [CO 2 ] >= 30% # Postcombustion (4% CO 2 ) CO 2 capture on concentrated flue gas * Favre, E. Bounaceur, R., Roizard, D.(2009),, Sep. Purif. Technol, 68, 30-36. 16 16

3- Integrated membrane / gas turbine process Capture ratio =90% Flue gas recycling (FGR) Natural gas O 2 enriched air (OEA) Cryogenic process Air Combustion chamber Gas Turbine Cooler 250 MW NGT GE REF = 0.39 Simulation software EES Z 1 Z Key variable parameters P in x in Compressor Membrane module P atm Y p =0.9 Permeate to CO 2 transport and sequestration N 2 CO 2 17

2- Integrated membrane / gas turbine process [, reference = - 15%, Combustion in air and without FGR] 4 Cost CO 2 Capture Co ost ( GJ/TCO 2 ) 3,5 3 25 2,5 2 MEA absorption reference - 73% 7.3% E= 2.7 GJ/ton 0 5 10 15 20 25 30 P IN (bar) Energy integration Energy Recovery Systems Heat exchanger -6.3% E= 1.5 GJ/ton - Significant improvement of the energy efficiency of the process - Membrane selectivity helps to improve the energy effiency B. Belaissaoui, G. Cabot, M.L. Cabot, D. Wilson, E., Favre Energy (2012) 38, 167 175 18

3- Conclusion and perspectives Major outcome of the study: Membrane + cryogeny: Potential energy decrease High selectivity ec is not needed (50 is enough) Membrane / OEA/ NGT Potential energy decrease Large selectivity helps The use of membrane unit in hybrid processes can offer attractive performances for diluted flue gas treatment Future work: Experiments +Trade-off CAPEX OPEX to be investigated 19

Stanbridge Capital Oil & Energy Hybrid Membrane Based Systems for CO 2 Capture on Natural Gas and Coal Power Plants PCCC2, Bergen, 18 th September 2013 Thank you for your attention Bouchra.belaissaoui@univ-lorraine.fr 20

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2- Integrated membrane / gas turbine process Improved approach: Energy Integration Flowsheet Flue gas recycling (FGR) Natural gas O 2 enriched air (OEA) Cryogenic process Combustion chamber e Gas Turbine Cooler Z 1 Z P in x in Compressor Membrane module P atm Y p =0.9 Permeate to CO 2 transport and sequestration Heat exchanger Expande er N 2 CO 2 Air Combustion chamber Z 1 Z Cooler Membrane module P atm Y p =0.9 Permeate Modified flowsheet: Cooler P in x in Heat exchanger - Energy Recovery System (Expander on the retentate) Net Power C FGR OEA C OEA Cryogenic process C Fuel Natural gas N 2, O 2 Gas Turbine C Memb Expander P atm - Heat exchanger (Retentate tt heating prior to the expander) Air 22

2- Integrated membrane / gas turbine process Integrated approach: Performances 3.5 Reference gas turbine cycle (config. A), =50 O2) rgy requireme ent (GJ/ ton CO E, overall ene 3 2.5 2 1.5 Config.B, =50 Config.B, =100 Config.B, =200 Reference gas turbine cycle (config.a), =100 Reference gas turbine cycle (config. A), =200-6.3% 1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 (heat exchanger efficiency) B. Belaissaoui, G. Cabot, M.L. Cabot, D. Wilson, E., Favre Chemical Engineering Science (2013) 97, 256 263 23

Influence of the membrane selectivity Selectivity CO 2 /N 2 1000 100 10 Upper Bound (Robeson 2008) Prospectives membranes Polaris TM (MTR) Commercial membranes 1 1 10 100 1000 10000 CO 2 Permeance, GPU Membrane selectivity 50 100 200 CO 2 membrane permeance (GPU) 1000 24

A membrane / MEA absorption hybrid process is (probably) not relevant 5 4.5 4 3.5 3 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 %CO2 Specific energy requirement of a MEA carbon capture process as a function of CO 2 inlet concentration in the flue gas 25

Hybrid process: Membrane preconcentration + cryogeny 9 of recovered CO2 ) 8 7 6 5 Cryogenic CO 2 capture is not efficient for low CO 2 content ryogenic unit (GJ/ton E c 4 3 2 1 Cryogenic CO 2 capture can be very efficient for high CO 2 content 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Inlet CO 2 mole fraction (x') Retentate Q in X in E M Q P X membrane P in =1bar Cryogeny P =1bar X out >90% T=30 C P out =110bar E C Q out Incondensable outlet 26

Hybrid process NGT / OEA / FGR: Selectivity helps 4000 Cost 1 3500 0.9 MJ/TCO 2 ) CO 2 Capture Cost ( 3000 2500 2000 1500 O 2 CO 2 0.8 07 0.7 0.6 05 0.5 0.4 X IN-CO2 - X O2 1000 03 0.3 0 5 10 15 20 25 30 P IN Significantifi improvement of the energy efficiency i of the process Membrane selectivity helps B. Belaissaoui, G. Cabot, M.L. Cabot, D. Wilson, E., Favre Energy (2012) 38, 167-175 27

Simulation results of the hybrid process (2) Energy requirement = f(x CO2 ) x in, CO2 100 Feed compression with ERS =50 (available performances) E (GJ/to on of recovere ed CO 2 ) 10 All Cryogeny, x in,co2 =0.05 All Cryogeny, x in,co2 =0.15 Standard MEA absorption All Cryogeny, x in,co2 =0.30 x in, CO2 =0.0505 x in,co2 =0.15 x in,co2 =0.3 1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Intermediate CO 2 mole fraction x' The hybrid process appears to be particularly interesting for intermediate CO 2 contents, i.e. around 15%, the main target of carbon capture studies. 28

Simulation results of the hybrid process (3) Minimum energy requirement = f(x in, CO2 ) CO2/N2 10 Feed compression with ERS E min (G GJ/ton of reco overed CO 2 ) Standard MEA absorption+compression 1 0.05 0.1 0.15 0.2 0.25 0.3 Inlet CO 2 mole fraction x in The minimum energy requirement decreases when CO 2 inlet content increases and also when membrane selectivity increases. The minimum energy consumption is slightly influenced by membrane selectivity (50 or 100) specially for x in, CO2 > 0.15. 29

Cryogenic separation: simulation Three-stage compression with intercoolers (Aspen software) ) P out = 1 bar x CO2 x out >98% P out =110bar CO 2 capture ratio >0.95 CO 2 purity (x out ) >0.98 Pump Isentropic efficiency : 0.8 Compressor isentropic efficiency : 0.85 30

3- Integrated membrane / gas turbine process Key variable parameters Natural gas O 2 Enriched Air E OEA Gas Turbine E CO2 Z 1 Z P IN X IN Membrane separation N 2 Cryogenic CO separation N 2, O 2 2 Flue gas Air CO 2 purity=90% recycling Capture ratio =90% 250 MW NGT GE REF = 0.39 Simulation software EES 31

Perspectives For medium oxygen purity production, alternative technology membrane air separation) could be investigated (PSA, 32

III- Performances for OEA feeding condition 2- Gas turbine efficiency Membrane selectivity CO 2 /N 2 =100, y CO2 = 0.9 0,4 0,8 0,35 ref 0,7 0,3 0,6 therm 0,25 0,2 0,15 0,1 AIR feeding st toech. line 0,5 0,4 0,3 0,2 X IN CO2 0,05 0 OEA feeding 0 0,2 0,4 0,6 0,8 1 Recycling ratio, Z 0,1 0 - The thermal efficiency ypasses through a maximum value as Z increases. - Concentrated CO 2 in the flue gas can obtained (x in, CO2 > 0.2) 33

Post-combustion Membrane process unit carbon principal capture and storage (CCS) technology A single stage membrane module Membrane Q in P upstream P in =1bar x in,co2 =0.15 Compressor CO 2 capture ratio = 90% P downstream Q in P out = 1 bar x CO2 Expander Retentate Permeate CO 2 rich stream Y= 90% Modeling framework :Cross-plug flow model 1 (M3Pro( software) ) Model hypothesis : Binary dry CO 2 /N 2 mixture Isothermal conditions. A strong parametric sensitivity of Isobaric condition in each side. both units and y and xin 34 1 Bounaceur R. et al, (2006) Energy, 31, 2556-2570. 2 N. Matsumiya et al, (2005) Separation and Purification Technology, 46, 26-32.

Cryogenic separation Three-stage compression with intercoolers (Aspen software) P out = 1 bar x CO2 x out >98% P out =110bar CO 2 capture ratio >0.95 CO 2 purity (x out ) >0.98 Pump Isentropic efficiency : 0.8 Compressor isentropic efficiency : 0.85 35