This invention relates generally to carbon capture and more specifically to methods and systems for capturing carbon dioxide.
Before carbon dioxide (CO2) gas can be sequestered from power plants and other point sources, it must be captured in a relatively pure form. On a mass basis, CO2 is the nineteenth largest commodity chemical in the United States, and CO2 is routinely separated and captured as a byproduct of industrial processes such as synthetic ammonia production, hydrogen (H2) production or limestone calcination.
Existing CO2 capture technologies, however, are not cost-effective when considered in the context of sequestering CO2 from power plants. Most power plants and other large point sources use air-fired combustors, a process that exhausts CO2 diluted with nitrogen. For efficient carbon sequestration, the CO2 in these exhaust gases must be separated and concentrated.
CO2 is currently recovered from combustion exhaust by using, for example, amine absorbers and cryogenic coolers. The cost of CO2 capture using current technology, however, can be as high as $150 per ton—much too high for carbon emissions reduction applications. Furthermore, carbon dioxide capture is generally estimated to represent three-fourths of the total cost of a carbon capture, storage, transport, and sequestration system.
Accordingly, there is a need for a new CO2 separation system and method to make CO2 separation and capture from power plants easier and more cost effective.
In one aspect, a carbon dioxide separation system includes a compressor for receiving an exhaust gas comprising CO2 and generate a compressed exhaust gas and a separator configured to receive the compressed exhaust gas and generate a CO2 lean stream. The separator includes a first flow path for receiving the compressed exhaust gas, a second flow path for directing a sweep fluid therethrough, and a material with selective permeability of carbon dioxide for separating the first and the second flow paths and for promoting carbon dioxide transport therebetween. The system further includes an expander coupled to the compressor for receiving and expanding the CO2 lean stream to generate power and an expanded CO2 lean stream.
In another aspect, a carbon dioxide separation system includes a compressor for receiving an exhaust gas comprising CO2 and generate a compressed exhaust gas and a membrane separator configured to receive the compressed exhaust gas and generate a CO2 lean stream. The membrane separator includes a first flow path for receiving the compressed exhaust gas, a second flow path for directing a sweep fluid therethrough wherein the sweep fluid is at a sub-atmospheric pressure and a material with selective permeability of carbon dioxide for separating the first and the second flow paths and for promoting carbon dioxide transport therebetween. The system further includes an expander coupled to the compressor for receiving and expanding the CO2 lean stream to generate power and an expanded CO2 lean stream.
In yet another aspect, a carbon dioxide separation system includes a compressor for receiving an exhaust gas comprising CO2 and generate a compressed exhaust gas and a facilitated transport membrane separator configured to receive the compressed exhaust gas and generate a CO2 lean stream The facilitated transport membrane separator includes a first flow path for receiving the compressed exhaust gas, a second flow path for directing a sweep fluid therethrough, wherein the sweep fluid is at a sub-atmospheric pressure and a material with selective permeability of carbon dioxide for separating the first and the second flow paths and for promoting carbon dioxide transport therebetween. The system further includes an expander coupled to the compressor for receiving and expanding the CO2 lean stream to generate power and an expanded CO2 lean stream.
In yet another aspect, an exhaust gas treatment system includes a compressor for receiving an exhaust gas comprising CO2 and generate a compressed exhaust gas, wherein the exhaust gas is generated from a coal gasification plant or a natural gas combined cycle power plant and a membrane separator configured to receive the compressed exhaust gas and generate a CO2 lean stream. The membrane separator includes a first flow path for receiving the compressed exhaust gas, a second flow path for directing a sweep fluid therethrough, wherein the sweep fluid is at a sub-atmospheric pressure and a material with selective permeability of carbon dioxide for separating the first and the second flow paths and for promoting carbon dioxide transport therebetween. The system further includes an expander coupled to the compressor for receiving and expanding the CO2 lean stream to generate power and an expanded CO2 lean stream and a post purification system and a compressing system to generate a high pressure CO2 rich stream.
In another aspect, a method for separating carbon dioxide includes compressing an exhaust gas comprising CO2 and generating a compressed exhaust gas and receiving the compressed exhaust gas in a separator and generating a CO2 lean stream The separator includes a first flow path for receiving the compressed exhaust gas, a second flow path for directing a sweep fluid therethrough wherein the sweep fluid is at a sub-atmospheric pressure and a material with selective permeability of carbon dioxide for separating the first and the second flow paths and for promoting carbon dioxide transport therebetween. The method further includes expanding the CO2 lean stream to generate power and an expanded CO2 lean stream.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
As shown in
The separation systems described herein enhance the driving forces for CO2 removal by membranes from the cooled compressed exhaust gas 24 comprising CO2 as the cooled compressed exhaust gas 24 is at high pressure. The pressure difference across the membrane, which pressure difference is the driving force for CO2 removal is further enhanced by operating the sweep fluid 36 at a sub-atmospheric permeate pressure. In some embodiments, the sweep fluid 36 is at a sub-atmospheric pressure of about 0.1 bar to about 0.5 bar. In one embodiment, the sweep fluid 36 is at a sub-atmospheric pressure of about 0.2 bar. Referring once again to
The membrane in the separation systems described here may comprise any membrane material that is stable at the operating conditions and has the required CO2 permeability and selectivity at the operating conditions. Possible membrane materials that are selective for CO2 include certain inorganic and polymer materials, as well as combinations comprising at least one of these materials. Inorganic materials include microporous carbon, microporous silica, microporous titanosilicate, microporous mixed oxide, and zeolite materials, as well as combinations comprising at least one of these materials.
Polymeric materials known to be selective for CO2 include, for example, certain polymer materials, such as polyethylene oxides, polyimides, and polyamides. While not to be limited by a particular theory, mechanisms for CO2 selectivity in polymeric materials include solution-diffusion and facilitated transport. In a solution-diffusion membrane the flux of CO2 is enhanced over the other gases in the gas stream by the virtue of CO2 having a higher solubility in the membrane, a higher diffusivity through the membrane or a combination of both. In a facilitated transport membrane, functional groups with a chemical affinity for CO2 are present within the membrane that allow a higher flux of CO2 relative to the other gases. Examples of facilitated transport membranes include polyethylenimine/poly(vinyl alcohol).
In practice, the membrane often comprises a separation layer that is disposed upon a support layer. The porous support can comprise a material that is different from the separation layer. Support layers for polymeric membranes can comprise polysulfone, poly(ether sulfone), Teflon, cellulose acetate, or polyacrylonitrile. Support materials for asymmetric inorganic membranes include porous alumina, titania, cordierite, carbon, silica glass (e.g., Vycor®), and metals, as well as combinations comprising at least one of these materials. Porous metal support layers include ferrous materials, nickel materials, and combinations comprising at least one of these materials, such as stainless steel, iron-based alloys, and nickel-based alloys. In addition, polymeric membranes can be disposed on polymeric or inorganic supports. Membranes can include polymeric materials such as polyethers and polyether blends and hybrid membranes such as silanized gamma-alumina membranes. Silanes, such as 2-acetoxyethyl, 2-carbomethoxyethyl and 3-aminopropyl, can be integrated with ceramic membranes to achieve selective CO2 transport.
Hybrid membranes that incorporate inorganic particles within a polymeric matrix can show enhanced CO2 selectivity properties at elevated operating conditions. Mixed matrix membranes that incorporate adsorbent inorganic particles such as zeolites or carbon within polymeric matrices also show enhanced properties at elevated operating conditions. This technique is not restricted to any particular membrane material or type and encompasses any membrane comprising any material that is capable of providing suitable levels of permeance and selectivity. That includes, mixed matrix membranes, facilitated transport membranes, hollow fiber membranes, spiral wound membranes, ionic liquid membranes and polymerized ionic liquid membranes.
In one embodiment, the separator is a facilitated transport membrane. As an alternative to conventional polymeric membranes, facilitated transport membranes may be used as they have the potential of achieving both high permeability and high selectivity. Facilitated transport membranes may selectively permeate CO2 by means of a reversible reaction of CO2 with an incorporated complexing agent (carrier) in the membrane, whereas gases such as H2, N2, and CH4 will permeate exclusively by the solution-diffusion mechanism.
In one embodiment, the exhaust gas 12 is at a temperature in the range between about 30° C. to about 700° C. This system can be utilized over a wide range of systems for any exhaust gas, for example, furnace exhaust, thermal oxidizers, metal processing or any other industrial process.
In one embodiment, sweep fluid 36 is a condensable fluid, like steam for example. In another embodiment, sweep fluid 18 can be one or more of the following: refrigerants; alcohols, like ethanol; hydrocarbons like butane; fluorinated and non-fluorinated hydrocarbons, ketones, ethers, and ethers; and siloxanes. In addition, while this invention is discussed in relation to CO2 capture systems, a material selective to other constituents within an exhaust gas steam, for example, CO, nitrous oxide (NOx), or acid gases like hydrogen sulfide (H2S), sulfuric acid (H2SO4) or hydrochloric acid (HCl) or other pollutants or species, may be utilized to capture the other constituents in a similar fashion.
There are several advantages for separating CO2 from exhaust gases using techniques described in the preceding sections. Typically post combustion separation of CO2 from any exhaust gas is not energy efficient due to lack of availability of elevated pressure in the exhaust stream. In the separation systems described herein, the exhaust gas is compressed to increase the CO2 partial pressure, which compression process allows the use of CO2 separation technologies such as membrane technology. The compression power required to compress the exhaust gas is partly recovered by expanding the CO2 lean stream in an expander coupled to the compressor. As described herein, the membrane permeate side is operated at a sub-atmospheric conditions, e.g. by operating a CO2 compression chain at sub-atmospheric inlet suction pressure (e.g. at about 0.2 bar). By this a higher pressure difference over the membrane is established at relative low compression power, as mainly the much smaller flow of the permeate side rich in CO2 has to be compressed in contrast to the larger feed side. This leads to increased driving forces for separation, and enables the use of membrane technology for CO2 capture. Due to the low permeate pressure (sub-atmospheric), steam at a temperature lower than 100° C. can be used for sweeping, as required by a lot of polymeric membrane materials. The separation systems described herein are easy to implement on all existing and future power plants, as no integration with the main power system is required. This separation system may also be used for CO2 rich flue gases from any industrial processes. Optionally, still heat recovery from the main power system could be implemented, including heat recovery from the hot gas turbine exhaust gas, or a gas turbine intercooler (if available). By (optionally) using the exhaust gas recirculation (shown in
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/564,912, Docket Number 207795-1, entitled “CARBON DIOXIDE CAPTURE SYSTEMS AND METHODS,” filed Nov. 30, 2006, which application is herein incorporated by reference.
Number | Date | Country | |
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Parent | 11564912 | Nov 2006 | US |
Child | 11959885 | US |