High Efficiency SOFC Power Cycles With Indirect Natural Gas Reforming and CO2 Capture

2015 ◽  
Vol 12 (2) ◽  
Author(s):  
Stefano Campanari ◽  
Matteo Gazzani
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
Gas Turbine ◽  
Co2 Capture ◽  
Heat Exchangers ◽  
High Efficiency ◽  
Power Production ◽  
Operating Conditions ◽  
Power Cycles ◽  
Power Cycle

Driven by the search for the highest theoretical efficiency, several studies have investigated in the last years the adoption of fuel cells (FCs) in the field of power production from natural gas with CO2 capture. Most of the proposed power cycles rely on high temperature FCs, namely, solid oxide FCs (SOFCs) and molten carbonate FCs (MCFCs), based on the concept of hybrid FC plus gas turbine cycles. Accordingly, high temperature FCs are integrated with a simple or modified Brayton cycle. As far as SOFCs are concerned, CO2 can be separated downstream the FC via a range of available technologies, e.g., chemical or physical separation processes, oxy-combustion, and cryogenic methods. Following a literature review on promising plant configurations, this work investigates the potential of adopting an external natural gas conversion section with respect to the plant efficiency. As a reference plant, we considered a power cycle proposed by Adams and Barton (2010, “High-Efficiency Power Production From Natural Gas With Carbon Capture,” J. Power Sources, 195(7), pp. 1971–1983), whose performance is the highest found in literature for SOFC-based power cycles, with 82% LHV electrical efficiency. It is based on a prereforming concept where fuel is reformed ahead the SOFC, which thus works with a high hydrogen content fuel. After reproducing the power cycle with the ideal assumptions proposed by the original authors, as second step, the simulations were focused on revising the power cycle, implementing a complete set of assumptions about component losses and more conservative operating conditions about FC voltage, heat exchangers minimum temperature differences (which were previously neglected), maximum steam temperature (set according to heat recovery steam generator (HRSG) practice), turbomachinery efficiency, component pressure losses, and other adjustments. The simulation also required to design an appropriate heat exchangers network, which turned out to be very complex, instead of relying on the free allocation of heat transfer among all components. Considering the consequent modifications with respect to the original layout, the net electric efficiency changes to around 63% LHV with nearly complete (95%+) CO2 capture, a still remarkable but less attractive value. On the other hand, the power cycle requires a complicated and demanding heat exchangers network and heavily relies on the SOFC performances, not generating a positive power output from the gas turbine loop. Detailed results are presented in terms of energy and material balances of the proposed cycles. All simulations have been carried out with the proprietary code GS, developed by the GECOS group at Politecnico di Milano.

High Efficiency SOFC Power Cycles With Indirect Natural Gas Reforming and CO2 Capture

2014 ◽  
Author(s):  
Stefano Campanari ◽  
Matteo Gazzani
Keyword(s):  
Fuel Cells ◽  
High Temperature ◽  
Fuel Cell ◽  
Natural Gas ◽  
Co2 Capture ◽  
Heat Exchangers ◽  
High Hydrogen ◽  
Power Cycles ◽  
Power Cycle ◽  
Natural Gas Reforming

Driven by the search for the highest theoretical efficiency, several studies have investigated in the last years the adoption of fuel cells in the field of power production from natural gas with CO2 capture. Most of the proposed power cycles rely on high temperature fuel cells, namely Solid Oxide Fuel Cells (SOFC) and Molten Carbonate Fuel Cells (MCFC), based on the concept of hybrid fuel cell plus gas turbine cycles. Accordingly, high temperature fuel cells are integrated with a simple or modified Brayton cycle. As far as SOFC are concerned, two main plant solutions can be identified depending on the integration with the natural gas reforming/shift section: (i) systems where natural gas is — partially or totally — internally reformed in the fuel cell and (ii) systems where natural gas is reformed before the fuel cell and the cell is fed with a high hydrogen syngas. In both cases, CO2 can be separated downstream the fuel cell via a range of available technologies, e.g. chemical or physical separation processes, oxy-combustion and cryogenic methods. Following a literature review on very promising plant configurations, this work investigates the advantages and limits of adopting an external natural gas conversion section with respect to the plant efficiency. As a reference plant we considered a power cycle proposed by Adams and Barton [8], whose performance is the highest found in literature for SOFC-based power cycles, with 82% LHV electrical efficiency. It is based on a pre-reforming concept where fuel is reformed ahead the SOFC which thus works with a high hydrogen content fuel. This plant was firstly reproduced considering all the ideal assumptions proposed by the original authors. As second step, the simulations were focused on revising the power cycle, implementing a complete set of assumptions about component losses and more conservative operating conditions about fuel cell voltage, heat exchangers minimum temperature differences, maximum steam temperature, turbomachinery efficiency, component pressure losses and other adjustments. Considering the consequent modifications with respect to the original layout, the net electric efficiency changes to around 66% LHV with nearly complete (95%+) CO2 capture, a still remarkable but less attractive value, while requiring a very complex and demanding heat exchangers network. Detailed results are presented in terms of energy and material balances of the proposed cycles. All the simulations have been carried out with the proprietary code GS, developed by the GECOS group at Politecnico di Milano.

Performance and Cost Analysis of Advanced Gas Turbine Cycles With Precombustion CO2 Capture

2008 ◽  
Vol 131 (2) ◽  
Author(s):  
Stéphanie Hoffmann ◽  
Michael Bartlett ◽  
Matthias Finkenrath ◽  
Andrei Evulet ◽  
Tord Peter Ursin
Keyword(s):  
High Pressure ◽  
Power Plant ◽  
Natural Gas ◽  
Gas Turbine ◽  
Co2 Capture ◽  
Gas Turbines ◽  
High Efficiency ◽  
Combined Cycle ◽  
Co2 Separation ◽  
The Cost

This paper presents the results of an evaluation of advanced combined cycle gas turbine plants with precombustion capture of CO2 from natural gas. In particular, the designs are carried out with the objectives of high efficiency, low capital cost, and low emissions of carbon dioxide to the atmosphere. The novel cycles introduced in this paper are comprised of a high-pressure syngas generation island, in which an air-blown partial oxidation reformer is used to generate syngas from natural gas, and a power island, in which a CO2-lean syngas is burnt in a large frame machine. In order to reduce the efficiency penalty of natural gas reforming, a significant effort is spent evaluating and optimizing alternatives to recover the heat released during the process. CO2 is removed from the shifted syngas using either CO2 absorbing solvents or a CO2 membrane. CO2 separation membranes, in particular, have the potential for considerable cost or energy savings compared with conventional solvent-based separation and benefit from the high-pressure level of the syngas generation island. A feasibility analysis and a cycle performance evaluation are carried out for large frame gas turbines such as the 9FB. Both short-term and long-term solutions have been investigated. An analysis of the cost of CO2 avoided is presented, including an evaluation of the cost of modifying the combined cycle due to CO2 separation. The paper describes a power plant reaching the performance targets of 50% net cycle efficiency and 80% CO2 capture, as well as the cost target of 30$ per ton of CO2 avoided (2006 Q1 basis). This paper indicates a development path to this power plant that minimizes technical risks by incremental implementation of new technology.

scholarly journals Corrosion and Erosion Behavior in Supercritical CO2 Power Cycles

2014 ◽  
Author(s):  
Darryn Fleming ◽  
Alan Kruizenga ◽  
James Pasch ◽  
Tom Conboy ◽  
Matt Carlson
Keyword(s):  
Carbon Dioxide ◽  
Stainless Steel ◽  
Intergranular Corrosion ◽  
Supercritical Co2 ◽  
Power Production ◽  
Operating Conditions ◽  
Working Fluid ◽  
Power Cycles ◽  
Power Cycle ◽  
Potential Issue

Supercritical Carbon Dioxide (S-CO2) is emerging as a potential working fluid in power-production Brayton cycles. As a result, concerns have been raised regarding fluid purity within the power cycle loops. Additionally, investigations into the longevity of the S-CO2 power cycle materials are being conducted to quantify the advantages of using S-CO2 versus other fluids, since S-CO2 promises substantially higher efficiencies. One potential issue with S-CO2 systems is intergranular corrosion [1]. At this time, Sandia National Laboratories (SNL) is establishing a materials baseline through the analysis of 1) “as received” stainless steel piping, and 2) piping exposed to S-CO2 under typical operating conditions with SNL’s Brayton systems. Results from ongoing investigations are presented. A second issue that SNL has discovered involves substantial erosion in the turbine blade and inlet nozzle. It is believed that this is caused by small particulates that originate from different materials around the loop that are entrained by the S-CO2 to the nozzle, where they impact the inlet nozzle vanes, causing erosion. We believe that, in some way, this is linked to the purity of the S-CO2, the corrosion contaminants, and the metal particulates that are present in the loop and its components.

Investigation of Printed Circuit Heat Exchangers for VHTRs

2008 ◽  
Author(s):  
Sai K. Mylavarapu ◽  
Xiaodong Sun ◽  
Justin Figley ◽  
Noah J. Needler ◽  
Richard N. Christensen
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
High Efficiency ◽  
Operating Conditions ◽  
Test Facility ◽  
Dynamics Modeling ◽  
Alloy 617 ◽  
Printed Circuit ◽  
High Temperature Materials ◽  
System Pressure

Very High Temperature Reactors (VHTRs) require high temperature (900–950 °C), high integrity, and high efficiency heat exchangers during normal and off-normal conditions. A class of compact heat exchangers, namely, the Printed Circuit Heat Exchangers (PCHEs), made of high temperature materials, found to have the above characteristics, are being increasingly pursued for heavy duty applications. A high-temperature helium experimental test facility, primarily aimed at investigating the heat transfer and pressure drop characteristics of the PCHEs, was designed and is being built at the Ohio State University. The test facility was designed for a maximum operating temperature and pressure of 900 °C and 3 MPa, respectively. Owing to the high operating conditions, a detailed investigation on various high temperature materials was carried out to aid in the design of the test facility and the heat exchangers. The study showed that alloy 617 is the leading candidate material for high temperature heat exchangers. Two PCHEs, each having 10 hot and 10 cold plates with 12 channels in each plate, are currently being fabricated from alloy 617 plates and will be tested once the test facility is constructed. To supplement the experiments, computational fluid dynamics modeling of a simplified PCHE model is being performed and the results for three flow rate cases of 15, 40, and 90 kg/h and a system pressure of 3 MPa are discussed. In summary, this paper focuses on the study of the high-temperature materials, the design of the helium test facility, the design and fabrication of the PCHEs, and the computational modeling of a simplified PCHE model.

Exergy Analysis of Gas-Turbine Combined Cycle With CO2 Capture Using Pre-Combustion Decarbonization of Natural Gas

2002 ◽  
Author(s):  
Hanne M. Kvamsdal ◽  
Ivar S. Ertesva˚g ◽  
Olav Bolland ◽  
Tor Tolstad
Keyword(s):  
Natural Gas ◽  
Electric Power ◽  
Gas Turbine ◽  
Co2 Capture ◽  
Exergy Analysis ◽  
Pressure Ratio ◽  
Power Production ◽  
Combined Cycle ◽  
Electric Power Production ◽  
Chemical Exergy

A concept for natural-gas fired power plants with CO2 capture has been investigated using exergy analysis. The present approach involves decarbonization of the natural gas by authothermal reforming prior to combustion, producing a hydrogen-rich fuel. An important aspect of this type of process is the integration between the combined cycle and the reforming process. The net electric power production was 47.7% of the Lower Heating Value (LHV) or 45.8% of the chemical exergy of the supplied natural-gas. In addition, the chemical exergy of the captured CO2 and the compression of this CO2 to 80 bar represented 2.1% and 2.7%, respectively, of the natural-gas chemical exergy. For a corresponding conventional combined cycle without CO2 capture, the net electric power production was 58.4% of the LHV or 56.1% of the fuel chemical exergy. A detailed breakdown of irreversibility is presented. In the decarbonized natural-gas power plant, the effect of varying supplementary firing (SF) for reformer-feed preheating was investigated. This showed that SF increased the total irreversibility and decreased the net output of the plant. Next, the effects of increased gas-turbine inlet temperature and of gas-turbine pressure ratio were studied. For the conventional plant, higher pressure led to increased efficiency for some cases. In the decarbonized natural-gas process, however, higher pressure ratio led to higher irreversibility and reduced thermal-plant efficiency.

Performance and Cost Analysis of Advanced Gas Turbine Cycles With Pre-Combustion CO2 Capture

2008 ◽  
Author(s):  
Ste´phanie Hoffmann ◽  
Michael Bartlett ◽  
Matthias Finkenrath ◽  
Andrei Evulet ◽  
Tord Peter Ursin
Keyword(s):  
High Pressure ◽  
Power Plant ◽  
Natural Gas ◽  
Gas Turbine ◽  
Co2 Capture ◽  
Gas Turbines ◽  
High Efficiency ◽  
Combined Cycle ◽  
Co2 Separation ◽  
The Cost

This paper presents the results of an evaluation of advanced combined cycle gas turbine plants with pre-combustion capture of CO2 from natural gas. In particular, the designs are carried out with the objectives of high efficiency, low capital cost and low emissions of carbon dioxide to the atmosphere. The novel cycles introduced in this paper are comprised of a high-pressure syngas generation island, in which an air-blown POX reformer is used to generate syngas from natural gas, and a power island, in which a CO2-lean syngas is burnt in a large frame machine. In order to reduce the efficiency penalty of natural gas reforming, a significant effort is spent evaluating and optimizing alternatives to recover the heat released during the process. CO2 is removed from the shifted syngas using either CO2 absorbing solvents or a CO2 membrane. CO2 separation membranes, in particular, have the potential for considerable cost or energy savings compared to conventional solvent-based separation and benefit from the high pressure level of the syngas generation island. A feasibility analysis and a cycle performance evaluation are carried out for large frame gas turbines such as the 9FB. Both short term and long term solutions have been investigated. An analysis of the cost of CO2 avoided is presented, including an evaluation of the cost of modifying the combined cycle due to CO2 separation. The paper describes a power plant reaching the performance targets of 50% net cycle efficiency and 80% CO2 capture, as well as the cost target of 30$ per ton of CO2 avoided. This paper indicates a development path to this power plant that minimizes technical risks by incremental implementation of new technology.

scholarly journals sCO2 Power Cycle Component Cost Correlations From DOE Data Spanning Multiple Scales and Applications

2019 ◽  
Author(s):  
Nathan T. Weiland ◽  
Blake W. Lance ◽  
Sandeep R. Pidaparti
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
Small Sample ◽  
Heat Sources ◽  
Cost Models ◽  
Cost Estimates ◽  
Power Cycles ◽  
Power Cycle ◽  
Wide Range ◽  
Economic Analyses

Abstract Supercritical CO2 (sCO2) power cycles find potential application with a variety of heat sources including nuclear, concentrated solar (CSP), coal, natural gas, and waste heat sources, and consequently cover a wide range of scales. Most studies to date have focused on the performance of sCO2 power cycles, while economic analyses have been less prevalent, due in large part to the relative scarcity of reliable cost estimates for sCO2 power cycle components. Further, the accuracy of existing sCO2 techno-economic analyses suffer from a small sample set of vendor-based component costs for any given study. Improved accuracy of sCO2 component cost estimation is desired to enable a shift in focus from plant efficiency to economics as a driver for commercialization of sCO2 technology. This study reports on sCO2 component cost scaling relationships that have been developed collaboratively from an aggregate set of vendor quotes, cost estimates, and published literature. As one of the world’s largest supporters of sCO2 research and development, the Department of Energy (DOE) National Laboratories have access to a considerable pool of vendor component costs that span multiple applications specific to each National Laboratory’s mission, including fossil-fueled sCO2 applications at the National Energy Technology Laboratory (NETL), CSP at the National Renewable Energy Laboratory (NREL), and CSP, nuclear, and distributed energy sources at Sandia National Laboratories (SNL). The resulting cost correlations are relevant to sCO2 components in all these applications, and for scales ranging from 5–750 MWe. This work builds upon prior work at SNL, in which sCO2 component cost models were developed for CSP applications ranging from 1–100 MWe in size. Similar to the earlier SNL efforts, vendor confidentiality has been maintained throughout this collaboration and in the published results. Cost models for each component were correlated from 4–24 individual quotes from multiple vendors, although the individual cost data points are proprietary and not shown. Cost models are reported for radial and axial turbines, integrally-geared and barrel-style centrifugal compressors, high temperature and low temperature recuperators, dry sCO2 coolers, and primary heat exchangers for coal and natural gas fuel sources. These models are applicable to sCO2-specific components used in a variety of sCO2 cycle configurations, and include incremental cost factors for advanced, high temperature materials for relevant components. Non-sCO2-specific costs for motors, gearboxes, and generators have been included to allow cycle designers to explore the cost implications of various turbomachinery configurations. Finally, the uncertainty associated with these component cost models is quantified by using AACE International-style class ratings for vendor estimates, combined with component cost correlation statistics.

scholarly journals Development of the PGT 25 High Efficiency Gas Turbine: Part 2 — Aerodynamic Design and Performance

1984 ◽  
Author(s):  
E. Benvenuti ◽  
B. Innocenti ◽  
R. Modi
Keyword(s):  
Gas Turbine ◽  
High Efficiency ◽  
Performance Testing ◽  
Operating Conditions ◽  
Aerodynamic Design ◽  
Direct Drive ◽  
Gas Generator ◽  
Full Load ◽  
Wide Range ◽  
Overall Performance

This paper outlines parameter selection criteria and major procedures used in the PGT 25 gas turbine power spool aerodynamic design; significant results of the shop full-load tests are also illustrated with reference to both overall performance and internal flow-field measurements. A major aero-design objective was established as that of achieving the highest overall performance levels possible with the matching to latest generation aero-derivative gas generators; therefore, high efficiencies were set as a target both for the design point and for a wide range of operating conditions, to optimize the turbine’s uses in mechanical drive applications. Furthermore, the design was developed to reach the performance targets in conjunction with the availability of a nominal shaft speed optimized for the direct drive of pipeline booster centrifugal compressors. The results of the full-load performance testing of the first unit, equipped with a General Electric LM 2500/30 gas generator, showed full attainment of the design objectives; a maximum overall thermal efficiency exceeding 37% at nominal rating and a wide operating flexibility with regard to both efficiency and power were demonstrated.

Advancement in Heated Spin Testing Technologies

2013 ◽  
Author(s):  
Hiroaki Endo ◽  
Robert Wetherbee ◽  
Nikhil Kaushal
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Material Properties ◽  
Gas Turbines ◽  
Multiple Scales ◽  
Thermal Conditions ◽  
Complex Stress ◽  
Operating Conditions ◽  
Mechanical Cycling ◽  
Testing Techniques

An ever more rapidly accelerating trend toward pursuing more efficient gas turbines pushes the engines to hotter and more arduous operating conditions. This trend drives the need for new materials, coatings and associated modeling and testing techniques required to evaluate new component design in high temperature environments and complex stress conditions. This paper will present the recent advances in spin testing techniques that are capable of creating complex stress and thermal conditions, which more closely represent “engine like” conditions. The data from the tests will also become essential references that support the effort in Integrated Computational Materials Engineering (ICME) and in the advances in rotor design and lifing analysis models. Future innovation in aerospace products is critically depended on simultaneous engineering of material properties, product design, and manufacturing processes. ICME is an emerging discipline with an approach to design products, the materials that comprise them, and their associated materials processing methods by linking materials models at multiple scales (Structural, Macro, Meso, Micro, Nano, etc). The focus of the ICME is on the materials; understanding how processes produce material structures, how those structures give rise to material properties, and how to select and/or engineer materials for a given application [34]. The use of advanced high temperature spin testing technologies, including thermal gradient and thermo-mechanical cycling capabilities, combined with the innovative use of modern sensors and instrumentation methods, enables the examination of gas turbine discs and blades under the thermal and the mechanical loads that are more relevant to the conditions of the problematic damages occurring in modern gas turbine engines.

Design Study of a Humidification Tower for the Advanced Humid Air Turbine System

2005 ◽  
Author(s):  
Hidefumi Araki ◽  
Shinichi Higuchi ◽  
Shinya Marushima ◽  
Shigeo Hatamiya
Keyword(s):  
Gas Turbine ◽  
Heat Exchangers ◽  
High Efficiency ◽  
Cooling System ◽  
Pressure Ratio ◽  
Humid Air ◽  
Air Turbine ◽  
Water Atomization ◽  
Air Cooler ◽  
Compressor Work

The AHAT (advanced humid air turbine) system, which can be equipped with a heavy-duty, single-shaft gas turbine, aims at high efficiency equal to that of the HAT system. Instead of an intercooler, a WAC (water atomization cooling) system is used to reduce compressor work. The characteristics of a humidification tower (a saturator), which is used as a humidifier for the AHAT system, were studied. The required packing height and the exit water temperature from the humidification tower were analyzed for five virtual gas turbine systems with different capacities (1MW, 3.2MW, 10MW, 32MW and 100MW) and pressure ratios (π = 8, 12, 16, 20 and 24). Thermal efficiency of the system was compared with that of a simple cycle and a recuperative cycle with and without the WAC system. When the packing height of the humidification tower was changed, the required size varied for the three heat exchangers around the humidification tower (a recuperator, an economizer and an air cooler). The packing height with which the sum total of the size of the packing and these heat exchangers became a minimum was 1m for the lowest pressure ratio case, and 6m for the highest pressure ratio case.

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