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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Computational fluid dynamics investigations of flow, heat transfer, and oxidation in heat recovery steam generator

Modern heat recovery steam generators (HRSGs) operate at elevated temperatures, leading to the formation of oxides inside the tubes of heat exchangers (HXs). This oxide growth reduces the heat recovery efficiency. Moreover, after reaching a certain critical thickness, some oxide scales detach from the tube surface (exfoliation), causing erosion damage to the components downstream. Predicting the metal temperature distribution and associated oxide thickness in the HXs of an HRSG can aid in mitigating these problems. Here, a computational fluid dynamics (CFD) model was developed within the commercial code STAR-CCM+ for the prediction of fluid flow, conjugate heat transfer, and associated oxidation in HRSGs. Moreover, a new Porous Media Model (PMM) method was developed to model the fin effect on the heat transfer in HX, which can substantially reduce the prohibitive computational costs of fin meshes. The developed CFD model was used to conduct a high-fidelity simulation of a real-scale HRSG to investigate flow, heat transfer, and oxide growth. The calculated oxide thickness on different tubes can be used to identify HX regions that require oxide-resistant coatings to prevent exfoliation and ensuing damages. Furthermore, this CFD framework can serve as a reference for future studies that intend to model and investigate high-temperature oxidation in HXs used for any applications.

42 ENGINEERING↗
DOE OSTI2022

Computational Fluid Dynamics Simulations to Predict Oxidation in Heat Recovery Steam Generator Tubes

Heat Recovery Steam Generators (HRSGs) are widely used across United States in combined cycle power plants to recover waste heat from the gas turbine (GT). HRSGs are used either to generate electricity or to produce process steam for industrial applications. The primary components of HRSG consists of a duct and a heat exchanger (HX). It is known across the power industry that the high temperature oxidation and ensuing exfoliation problem is a major cause for the damage of HX materials of HRSG. Alloys and/or coatings that can prevent or mitigate oxidation are very expensive, therefore they must be used or applied on the select regions of the HX tubes where the tendency of oxide formation is the highest. The main goal of this project is to identify such regions through Computational Fluid Dynamics (CFD) simulations. Therefore, in this work, we developed a CFD framework using commercial code StarCCM+ for the prediction of the fluid flow and heat transfer in a HRSG and associated oxidation inside the tubes of the HX. The developed CFD framework was verified and validated with experimental data before deployment. We also developed an innovative method to model the effect of the fins on the heat transfer and the pressure drop using a porous media model (PMM) approach to keep the mesh size within reasonable limits. After validation, we performed high-fidelity CFD simulations of a real-scale HRSG using the PMM, with High Performance Computing (HPC) resources of ORNL. From the simulation results, we acquired oxide thickness maps for all the tubes of the select HX sections of HRSG prone to oxidation. These oxide maps can inform regions of the HX tubes that requires oxide-resistant coatings, thereby guiding engineers for cost-efficient manufacturing of the HX that can combat oxidation in HRSGs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

ADVANCED THERMAL-HYDRAULIC MODEL OF HEAT RECOVERY STEAM GENERATORS

Steam-side oxidation at elevated temperatures in heat recovery steam generators (HRSGs) can lead to overheating of local tubes, potential oxide scale exfoliation, and damage to critical equipment. Predicting the oxide growth distribution requires detailed knowledge of the distribution of tube metal temperatures. To address these challenges, a computational fluid dynamics (CFD) model of a high-pressure superheater (HPSH) was developed within the Siemens’ STAR-CCM+ CFD commercial software. The HPSH section of the steam generator was selected for modeling because of its high oxidation rates.The model development included several steps. In the first step, an oxidation model based on a parabolic oxidation relationship was implemented. The oxidation growth predicted by the model was then verified for a full-load boiler operation case. In the second step, a three-dimensional CFD model was developed to account for the thermal and flow physics involved in HRSGs. The CFD model was then verified and validated on a simplified geometry that contained six row-tubes which mimicked the tube arrangements of an HPSH section. Numerical results compared well with published experimental results. In the third step, the oxidation model was coupled to the HRSG’s CFD model, and a comparison study was performed for two cases: (a) regular finless tubes and (b) finned tubes. Preliminary results showed that the oxide thickness predicted by the case with tube fins was higher compared to that of the finless tube case, thus demonstrating the need to model the effects of the tube fins on oxide thickness.

Panicker, Nithin↗
DOE OSTI2021

Impact on Cycle Efficiency of Small CHP Plants from Increasing Firing Temperature Enabled by AM of Turbine Blades

Combined Heat and Power (CHP) systems are gaining popularity because of their potential for high overall thermodynamic efficiency and increased need for distributed power generation. Most CHP systems include a gas turbine for electricity generation and a heat recovery steam generator (HRSG) for steam generation. The steam can be used to power a steam turbine for additional electricity generation or to drive rotating equipment, for space heating, for absorption chillers, etc. A CHP cycle configuration is often driven by the ‘principal’ utility for the facility that it services; steam or electricity. In either case, performance improvements in the gas turbine have the potential to increase the steam and power output from the cycle, which is a direct result of improvements in the gas turbine efficiency and power output. One possible opportunity to improve an existing gas turbine’s performance is to increase the firing temperature with improved turbine cooling and increased compression ratio.<br>In this study, the impact on CHP cycle performance from increasing the turbine firing temperature by 100 °C and improving the turbine blade cooling for a 6-MW scale gas turbine is estimated using an analytical cooled gas turbine model and a steam cycle model. A sensitivity analysis was performed to understand the impact of increasing the internal cooling effectiveness, thermal barrier coating performance and blade material upgrades on gas turbine and CHP cycle efficiency. The impacts of turbine blade cooling improvements were studied for three common CHP cycle configurations identified from the literature. Various definitions for CHP cycle efficiency from the literature are used in the comparisons. The results showed that a 100 °C increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. Studied engine upgrades showed potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.<br>

Uysal, Selcuk Can↗
DOE OSTI2025

Synchronous Machine Governor Upgrade

Conventional generation sources play a critical role in the stability and reliability of the electrical grid, particularly as we transition towards more renewable energy sources. To understand and accurately emulate their behavior for optimizing grid operations and ensuring seamless integration with renewable technologies, it is essential to better emulate the grid- and plant-level impacts of conventional generation sources, such as natural gas (NG) driven heat recovery steam generators (HRSGs) and combustion turbines (CTs). Therefore, a governor model is developed in a programmable logic controller (PLC) to investigate the performance of the conventional generator under various dynamic operating conditions and to identify the impact on grid stability in a controlled environment. The governor model aims to enable the hardware-in-the-loop (HIL) based emulation of these conventional generation sources using the existing 2 MVA synchronous machine/generator that is driven by a flexible 2.5 MW variable speed drive. This setup will allow us to replicate the dynamic characteristics and response behaviors of NG-driven HRSGs and CTs. The controls for the emulated conventional plants follow the industry standard and are adjustable, ensuring they accurately reflect the operational capabilities and limitations of real-world systems. These controls include load-following capabilities, ramp rates, startup and shutdown sequences, and emissions characteristics. By incorporating these adjustable controls, we aim to capture the nuanced impacts of conventional generation, such as their ability to provide ancillary services like frequency regulation, voltage support, and spinning reserve. In this report, we simulate two types of dynamic operations: grid-connected and islanding. For each dynamic operation, representative starting sequences are tested, including turbine purge, ignition, speed ramping up, generator excitation and synchronizing, and breaker close. The HIL based tests provides insights for field deployment, specifically the high-fidelity governor model provides results to predict the potential stability and reliability risk and suggest possible integration measures (e.g., generation and load balancing, tuning of governor control parameters). Ultimately, this enhanced emulation capability will be integrated into our Advanced Research on Integrated Energy Systems (ARIES), enabling us to conduct comprehensive studies on the interactions between conventional and renewable energy sources. By better understanding these interactions, we can develop strategies to optimize the overall performance and reliability of the grid. This will support the deployment of advanced grid management techniques, such as demand response, grid-forming inverters, and energy storage systems. The main contributions are summarized as follows: (1) This report introduces a PLC-based governor model for gas turbines. This model accurately simulates the dynamic behavior of conventional generation sources under various operational scenarios; (2) The model is integrated with an HIL testbed that includes a 2.5 MW variable speed drive and a 2 MVA synchronous machine. This setup enables realistic, real-time emulation of conventional power plants, particularly NG driven HRSGs and CTs; (3) The developed model is adaptable to various gas turbine configurations and allows for precise control over parameters such as MW ramp rates. This flexibility makes it a valuable tool for future research and industry collaboration; and (4) By incorporating the model into the National Renewable Energy Laboratory's Advanced Research on Integrated Energy Systems, the report lays the groundwork for future studies on interactions between conventional and renewable energy sources, enhancing the ability to develop advanced grid management strategies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Hydrogen Storage for Load-Following and Clean Power: Duct-firing of Hydrogen to Improve the Capacity Factor of NGCC Plants (Final Report, Phase II Pre-Front End Engineering Design Study)

GTI Energy (GTI) and team members Southern Company Services (SCS), Pacific Gas & Electric (PG&E) and the Electric Power Research Institute (EPRI) performed a Phase II Pre-Feed Study under contract DE-FE0032008 for Hydrogen Storage for Load-Following and Clean Power. The configuration of the proposed system consists of subsystems for on-site H 2 production, on-site H 2 storage (up to 54 MWth in commercial vessels) and H 2 combustion in a duct burner in a Heat Recovery Steam Generator (HRSG) integrated with an existing fossil asset. Here, the firing rate of the duct burner is varied to let the plant respond to fluctuations of electrical load and H 2 production is relatively constant by storing H 2 . The proposed system is an improvement over alternate low carbon dispatchable power options. Technoeconomic analyses show H 2 produced with GTI’s patented Compact Hydrogen Generator (CHG) with inherent carbon capture will be lower cost (Levelized Cost of Hydrogen, LCOH) relative to hydrogen produced with a Steam Methane Reformer (SMR) with an amine system for carbon capture. This lower cost hydrogen enables our integrated system to deliver electricity (Levelized Cost of Electricity, LCOE) at 17.4% lower cost relative to a SMR sourced H 2 -fired HRSG (with an amine system for carbon capture) – Steam Turbine Generator (STG). Our analysis using EPRI’s US REGEN macroeconomic model shows our system will have significant demand in the power market and therefore require significant capacity expansion (CHG plants built to deliver hydrogen) to deliver low cost, low carbon power. In Phase II, our Team has completed a detailed system definition including the development of process models, definition of battery limits, Process Flow Diagrams (PFDs), Piping and Instrumentation Drawings (P&IDs), and a plant layout. A preliminary design for the key components of the CHG was developed including component lists & specifications. An evaluation of environmental and permitting considerations was completed and included the development of an Environmental Information Volume (EIV). The duct burners, which are flexible and can burn hydrogen and/or natural gas, were defined and initial CFD analyses were completed.

03 NATURAL GAS↗
DOE OSTI2022

Cyber-Attack Detection and Accommodation for the Energy Delivery System

The goals of this project were to create a software system with a suite of key algorithms for cyber-attack detection and accommodation providing domain layer protection for critical power generation assets. Example assets included gas and steam turbines, heat recovery steam generators, and electrical generators. The aggressive algorithm goals were aimed at reducing the false positive rates in threat detection to <1% using learnings from many evolving disciplines (power turbine and generator physics, power system modeling, modern control theory, system identification, machine learning, deep learning, mathematics and data science). Additional goals for the algorithms involved localizing threats on-the-fly to know in which monitoring node the effects of attacks are present, and then providing accommodation to keep the system running uninterrupted much of the time in the presence of the attack. Accommodation had a performance goal of providing resiliency when up to 50% of monitoring nodes are in an attack state.

cybersecurity, cyber-physical↗
DOE OSTI2023

Creation of Multiple Effect Evaporator and Combined Cycle Modelica Modules, and Optimization of Potable Water Generation from Saltwater Sources (Final Technical Report)

Modelica models for a Heat Recovery Steam Generator (HRSG) and Multiple Effect Evaporator have been developed. These models have been validated against results from literature and from an actual cogeneration system on the campus of NC State University. The models are capable of connecting to other components to create multi-input, multi-output energy systems with storage, also known as integrated energy systems. An existing 35 MW gas turbine model is connected to the HRSG model created for this project to produce 9 bar steam. The high pressure steam feeds a backpressure steam turbine from the library to generate additional electric power. 2 bar steam leaves the turbine to supply an 8 effect MEE to generate water for a community. As part of the effort, three research papers were submitted (two published in ANS Proceedings and one submitted to Applied Energy).

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Synergistic heat pumped thermal storage and flexible carbon capture system

A power plant system is disclosed. The power plant system includes a combustor configured, a turbine configured to generate electricity, a heat exchanger and a steam turbine, a carbon capture system configured to remove at least a portion of carbon-based gasses from the flue gas downstream from the heat recovery steam generator, and a thermal storage system including a hot storage unit configured to store thermal energy at a hot temperature, the hot temperature greater than ambient temperature. The power plant is configured to operate in at least a first mode for storing thermal energy in the thermal storage system and a second mode for releasing the stored thermal energy from the thermal storage system and during the second mode, heat stored in the hot storage unit is transferred to the carbon capture system.

Bandhauer, Todd M.↗
DOE OSTI2022

Combined Cycle Integrated Thermal Energy Storage “CiTES” (Final Scientific/Technical Report)

The Phase I of this project confirmed the technical feasibility of a Combined Cycle integrated Thermal Energy Storage “CiTES” system, calculated the key performance parameters like power efficiency and costs, and proved its commercial value with full-year simulations for several US electricity markets with high degree of variable renewable generation and volatile hourly electricity prices. The core element of this project is the Electro Thermal Energy Storage (ETES) technology from Siemens Gamesa Renewable Energy GmbH, using thermally stable and inexpensive volcanic rocks as storage material and air as heat transfer medium. This technology is backed by more than 10 years of experience and a 440MMBTU (130MWh-th) pilot plant in Hamburg, Germany, which is in operation since 2019. The integration of this thermal storage in an existing combined cycle power plant (CCPP) is typical power plant technology without any major technology risks. It allows the storage of inexpensive renewable energy during times of surplus renewable generation and the discharge of this energy in times of high energy demand when the fossil plant is in operation. This supplements the fossil power generation with CO2-emission-free energy. The secondary effect of the CiTES system is that a small part of the stored thermal energy is used to keep the heat recovery steam generator (HRSG) and steam turbine (ST) of the combined cycle power plant in hot and ready-to-start condition. This enables the plant to start rapidly when fossil generation is required to satisfy demand as soon variable generation drops off in the evenings or during cloud cover and calm wind periods. Without pre-warming of the HRSG and ST, the CCPP would need several hours for a cold or warm start, burn a lot of gas and release high NOx emissions during start and wouldn’t be able to use the short times of high energy prices in an efficient or economical manner. The economic parameters of CiTES were determined by a full year “8760” simulation using a data set calculation for each of the hours of the year, and historical electricity and gas prices. For consistency, the simulations were focused on the pre-COVID year 2019. The financially most attractive markets were in the Energy Reliability Council of Texas (ERCOT) region, which allowed substantial value generation with arbitrage (charge with cheap energy during renewable surplus times and discharge when energy is needed and expensive). The improvement of flexibility with the CiTES system by pre-heating and warm-keeping of the CCPP allowed for additional power generation during short time periods when demand is high but renewable generation is down; when the hourly energy prices are highest in these markets. The simulations are based on 2019 data, when ERCOT had 27GW of installed photovoltaic (PV) and wind generation. They showed that the created revenue with the prototypically sized CiTES system of 1,000MMBTU (300MWh-th) falls a little bit short of what is expected from a commercially viable investment. The system has optimization opportunities for cost reduction and increased effectiveness which will be realized during a potential Phase II Pre-FEED study following this project. Furthermore, it is safe to assume that a lot of renewable generation capacity will be added all over the US in the coming years. As an example, ERCOT is predicting to more than double its renewable generation from 27GW in 2019 to a forecasted 63GW in 2023. This will increase the amount of renewable overproduction exponentially. This rapid increase of local overproduction and the need to curtail renewable generation is well documented by the California ISO (www.CAISO.com / managing oversupply). However, the simulations also revealed a weakness in the structure of the electricity markets in the US. More specifically, when electricity prices are very low and approaching negative levels, the owners of Variable Renewable Energy (VRE) will curtail a part of their facility to stabilize the price by reducing supply. This results in a situation in which storage facilities, which are integrated in existing fossil assets and don’t have the behind-the-meter benefit of a VRE, won’t be able to purchase low cost – otherwise curtailed – renewable energy off the grid. A special tariff, which motivates VRE owners to sell otherwise curtailed renewable energy to storage facilities (Hydrogen, thermal, pumped hydro, etc.) can solve this issue. The implementation of such a regulating tariff by Independent System Operators, thus avoiding renewable curtailment, is a pre condition for successful commercialization for renewable energy storage technologies. With this advancement of design and technology and improvements in the market environment, it can be expected that the Combined Cycle integrated Thermal Energy Storage proves itself as an important innovation to keep highly efficient, natural gas-based power generation economically successful and relevant for the power industry in the United States of America.

Wolf, Thorsten↗
DOE OSTI2024

Cost and Performance Estimates for State-of-the-Art and Advanced 1×1 H-Class Natural Gas-Fired Power Plants

As an extension of NETL's Fossil Energy Baseline for Electricity Generating Units Volume 1: Coal and Natural Gas to Electricity (FEB Rev 4a, this study develops cost and performance estimates for analogous NGCC cases using a state-of-the-art 2023 vintage H-Class CT in a 1×1 configuration, where a single combustion turbine and heat recovery steam generator are coupled to a single steam turbine on a common shaft. These 1×1 H-Class cases are used to develop cost and performance estimates of X-Class 1×1 NGCC cases with advanced performance characteristics, analogous to NETL’s cost and performance projections report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Economic viability of using thermal energy storage for flexible carbon capture on natural gas power plants

Fossil fuel-based power plants generate 80% of the electricity in the United States and provide a reliable generation source for both base and peak power demands. These plants are expected to adapt to changes in environmental policies that will require carbon management with carbon capture and storage (CCS) representing a possible solution. Current solvent-based CCS has a detrimental impact on a power plant's performance due to large heat loads required for carbon capture solvent regeneration. This parasitic load restricts the power plant's output and operation flexibility. Therefore, this study evaluates the feasibility of using thermal storage technologies for natural gas combined cycle (NGCC) power plants coupled with CCS to minimize the impact of solvent regeneration and enable the plant to operate at peak power output. Thermal storage can minimize the impact of CCS on the power plant by providing the heat load required for solvent regeneration during times of peak demand which will allow the plant to operate unrestricted and at full power. In total, fifteen unique thermal storage configurations were evaluated from three thermal storage categories: Brayton cycle heat pump, vapor compression heat pump, and heat recovery steam generator steam extraction for storage. The viability of these systems was determined by evaluating each configuration on thousands of real-world Locational Marginal Pricing (LMP) profiles from the New York Independent System Operator and California Independent System Operator electricity markets using a techno-economic analysis. Afterwards, results were compared to the performance of a base power plant (NGCC with CCS and no thermal storage) to determine the impact of thermal storage on power plant economics. Overall, six of the thermal storage configurations performed better than base CCS enabled power plant on between 11.5% and 38.7% of the LMP signals evaluated. The best performing configuration was a vapor compression heat pump that used flue gas as the working fluid and had both hot and cold thermal storage units. This configuration performed better than the base CCS power plant on 38.7% of the LMP profiles. The results of this study show thermal storage can mitigate the economic impact of carbon capture solvent regeneration on NGCC power plants. Discussion focuses on the impact of electricity pricing on the optimal thermal storage system, the advantages and disadvantages of the systems evaluated, and identifies limitations with the study.

25 ENERGY STORAGE↗
DOE OSTI2022

Hydrogen Storage for Load-Following and Clean Power: Duct-firing of Hydrogen to Improve the Capacity Factor of NGCC Plants (Final Report, Phase I Conceptual Study)

The 12-month Feasibility study in Phase I study was completed and confirmed the system is feasible and the proposed system is an improvement over alternate low carbon dispatchable power options. Our demonstration will include 54 MWh of hydrogen storage. CO 2 capture inherent to the CHG process can capture 90% of the CO 2 (with upgrades to >98%) in a commercial system (~300 MWth) for sequestration or other uses. The hydrogen will be utilized in a duct burner in a Heat Recovery Steam Generator (HRSG) integrated with the existing Southern Company fossil asset. Here, the firing rate of the duct burner is varied to let the plant respond to fluctuations of electrical load. However, H 2 production is relatively constant by storing H 2 , and revenues are improved by arbitrage between use of low-cost off-peak variable electricity generation or use of stored H 2 under peak demand. The study enabled the fidelity of the concept to be improved and allowed identification of the requirements for the system. Defining the individual system and component requirements was performed via system requirements review with the whole team. These requirements were then incorporated into/iterated with our Heat & Mass Balance models and process flow diagrams were generated to reflect the overall system. This information was then used to complete the TEA and show economic feasibility. Our system generates power at 17.4% lower cost than other low carbon approaches for the H 2 generation, H 2 compression and storage, carbon sequestration, and HRSG added electricity production for a large-scale duct-fired system. Our team recommends completing the Phase II Pre-FEED study for the proposed system as the next step for the project and its tasks will achieve the overall objective and be ready to launch the FEED. The Pre-FEED tasks include updating the requirements, Concept of Operations, plant scope/process description, component modeling, system modeling, performance estimates, emission estimates, block flow diagrams, fluid/process conditions (PFD), utility usage, and facility sizing/definition. The approach will be to complete these updates in a greater level of detail for the selected site. The approach for developing the EIV is to use the updated results, including model outputs, for carbon dioxide and waste streams.

03 NATURAL GAS↗
DOE OSTI2026

Solar Heat for Industrial Processes: Integration with Chemical Reactors

The integration of solar thermal systems with chemical reactors has been proposed as part of a larger effort to develop and deploy solar heat for industrial processes (SHIP) technologies. A strong motivation for SHIP processes and technologies is the potential for high thermal efficiency coupled with low-cost thermal energy storage (TES) which can enable commercial deployment of such systems. While there are different ways to categorize SHIP technologies, one important such distinction is between directly irradiated systems and indirect off-sun process driven by a SHIP system. While directly irradiated systems can provide high thermal efficiencies and high fluxes, they usually require complex engineering solutions due to the need for redesigning the established processes and unit operations. In most cases, it is also more challenging to couple such a process to a TES system, losing some of the benefits of SHIP. On the other hand, using a SHIP system to drive an industrial process off-sun can allow better integration with existing process chains, easier TES capabilities, and potential for more applications fitting a specific SHIP technology. However, the integration of SHIP systems with the industrial processes is not fully explored in detail, especially in the case of high-temperature processes such as reforming, cracking, cement manufacturing, and iron/steelmaking. Many of these systems require heating fluxes of >50 kW/m^2, supplied via combustion of hydrocarbons in a fire box and benefitting from radiative heat transfer between the flue gases and the reaction zones. As such, using SHIP systems for such processes is more complex than providing the same thermal input in the form of a heat transfer medium (HTM) entering the reactor, kiln, or furnace. Moreover, in case convective heat transfer using SHIP is envisioned, for example using supercritical CO2 as the HTM from a particle receiver, the thermal integration might be more challenging than initially envisioned: lower heat transfer coefficients and limited approach temperature might require large flow rates, causing a mismatch between the process thermal requirements and the thermal capacity of the SHIP system. In addition, even if the heat exchange between SHIP and reactor is effective, there is still a cold leg HTM at the reaction temperature or slightly below it. Chemical plants usually include a set of heat exchangers, heat recovery steam generators, and even power generation units - in a tightly integrated design - to recover the flue gases which are eventually vented. With SHIP systems mostly operating on a closed HTM loop, bottoming the cold leg is crucial. In this talk, we will present different modeling results for a variety of syngas production reactions, using catalytic and chemical looping processes, and discuss some of the challenges and design considerations for off-sun chemical reactors using SHIP systems.

14 SOLAR ENERGY↗
DOE OSTI2020

DICE-gas turbine compound reheat combined cycle

Coal-fired Direct Injection Carbon Engine – Gas Turbine (DICE-GT) Compound-Reheat Combined Cycle (CRCC), is a combined cycle power plant comprising a multiplicity of coal-fired reciprocating internal combustion engines (RICE), which is commonly referred to by the acronym DICE (Direct Injection Carbon Engine); a natural gas-fired gas turbine (turbine and combustor); a heat recovery steam generator (HRSG); a steam turbine generator; and an integrally geared and intercooled centrifugal air compressor. Finally, the concept uses coal-water slurry/fluid in the DICE and natural gas (or hydrogen) in the gas turbine for unmatched efficiency (well above 50% net LHV) and modularity (block sizes of 120, 240 and 360 MW) with easy adaptability to carbon capture and sequestration with minimal additional cost, complexity and performance hit.

42 ENGINEERING↗
DOE OSTI2022

Front-End Engineering Design Study for Retrofit Post-Combustion Carbon Capture on a Natural Gas Combined Cycle Power Plant

The objective of the project is to conduct a Front-End Engineering Design (FEED) study to determine the technical and economic feasibility of installing a retrofit, post-combustion, carbon capture facility on a commercially operating, natural gas-fired, combined cycle (NGCC) power plant. The Electric Power Research Institute (EPRI), California Resources Corporation (CRC), and Fluor Corporation used Fluor's Econamine FG Plus SM (EFG+) conducted the FEED study for capturing CO 2 produced by CRC's 550 MWe Elk Hills Power Plant (EHPP), located in the Elk Hills Oil Field near Tupman, Kern County, California. The EHPP was commissioned in 2003 and is powered by two General Electric 7FA gas turbines, with two heat recovery steam generators (HRSGs) providing steam to a General Electric D11 steam turbine. The target capture amount is 4,000 tonnes CO 2 /day for use in either enhanced oil recovery or dedicated geological saline storage located on CRC property at or nearby EHPP. This CO 2 is captured from a combination of the CO 2 emitted from the flue gas from EHPP and the flue gas generated from a natural gas-fired auxiliary boiler that supplies steam to the EFG+ process.

03 NATURAL GAS↗
DOE OSTI2022

Front-End Engineering Design for Piperazine with the Advanced Stripper

This Department of Energy (DOE) funded project was executed with the goal of preparing a Front-End Engineering Design (FEED) for the capture and compression of 90% of the CO2 that would normally be emitted from an existing natural gas combined cycle (NGCC) plant. The FEED focused on the application of the piperazine advanced stripper (PZAS) process at Mustang Station of the Golden Spread Electric Cooperative (GSEC), which consists of two gas turbines with common heat recovery steam generator (HRSG). The University of Texas at Austin (UT) served as the prime contractor, and subcontracted AECOM Technical Services and Trimeric Corporation to support FEED development. This project team has worked together to advance PZAS for more than a decade. ExxonMobil, Chevron, and Total provided project co-funding. The objectives of this work included: 1. To advance engineering design such that a comprehensive estimate for the total installed cost of a full-scale PZAS CO2 Capture Plant with CO2 compression can be developed on an existing NGCC power plant. a. These detailed costs can also be used to qualify PZAS and other related second generation (2G) amine scrubbing processes for use on cogeneration facilities in refineries and chemical plants that use gas turbines with HRSGs to produce steam. b. These detailed costs will help qualify 2G amine scrubbing for use on NGCC power plants and establish a more accurate baseline cost to be used as a target by other capture technologies. 2. To provide cost details to be used in the economic optimization of the process features of PZAS and other 2G amine scrubbing processes. 3. To provide DOE with a more detailed understanding of carbon capture costs in a commercial application, enabling DOE to better design its R&D program to improve the economics for carbon capture. 4. To provide the host site and cost share partners with the information necessary to determine whether a commercial project to capture and use CO2 for enhanced oil recovery (EOR) or for sequestration can be justified (when accounting for the 45Q tax credit). A key component of the FEED is the estimated total installed cost, which provides a basis for the likely capital investment necessary to implement the PZAS carbon capture process at this location and scale. In combination with the included economic analysis, which accounts for potential revenue from the produced CO2, potential avenues to profitability are explored. The major findings of the FEED are as follows: The Mustang Station PZAS CO2 Capture Plant estimated total project cost of $698 MM of which $384 MM was direct costs. The annual operating costs were $32.6 MM. The total investment for a PZAS facility at Mustang Station is $725 MM. This estimate includes owner’s cost of $25 million and a contingency of $110 MM. • The study estimated the CO2 capture plant at Mustang Station would generate CO2 at $110/tonne for EOR, assuming a 12% IRR (internal rate of return) and an 85% capacity factor. For CO2 storage, the same case would achieve a 12% IRR at about $114/tonne. At a capacity factor of 52%, the storage and EOR cases would break even when carbon is priced ~$150/tonne. The economic analysis determined that the capacity factor and utility pricing, among other variable factors, had a significant effect on the economics and will need additional studied. • The energy penalty of the PZAS plant would be about 46 MW in connected power and 35 MW in operating load. The natural gas requirement (for the Gas Boiler package) would be about 354 MMBTU/hr. • The FEED revealed no major risks in process maturity. However, some areas were outlined for further engineering during detailed design, which included the Gas Boiler system, general arrangement and site layout, air coolers, schedule development, and optimization of the process for higher CO2 removal. • If PZAS were to be implemented at another host site, additional opportunities for cost reduction for would include cost reduction through use of cooling water and steam extraction.

03 NATURAL GAS↗