This application relates generally to unmixed fuel processors, and more particularly, to systems and methods for producing electricity and/or hydrogen using unmixed fuel processors.
With its abundant domestic supply, coal is one of the most secure, reliable, and affordable energy supplies for the U.S. today, gasification of coal to produce electricity is being commercially introduced as Integrated Gasification Combined Cycle (IGCC) power plants. However, one of the major problems in modern industrial society is the air pollution by conventional combustion systems based on fossil fuels. The oldest recognized air pollution problem is the emission of smoke. In modern boilers and furnaces, smoke emissions could be eliminated or at least greatly reduced by the use of Over Fire Air (“OFA”) technology. Other types of air pollution produced by combustion include particulate emissions such as fine particles of ash from pulverized coal firing, oxides of sulfur (SO2 and SO3), carbon monoxide emissions, volatile hydrocarbon emissions and the release of two oxides of nitrogen, NO and NO2. More recently, the problem of global warming due to greenhouse gas emissions of CO2 from power plants and other combustion systems has become a matter of serious environmental concern.
Another major technological problem concerns the use of coal as a fuel for powering gas turbines. Gas turbines are the lowest capital cost systems available for generating electrical power. Since the thermodynamic efficiency of gas turbines increases with increasing turbine inlet temperature, efforts to improve turbine efficiency generally involve increasing the turbine inlet temperature to higher levels. As a result, turbine blades and other components have been engineered to tolerate increasing high inlet temperatures. It is well known that the hot gases produced by coal firing contain fly ash (which is erosive to turbine blades). In the presence of this erosive fly ash, the maximum service temperature at which turbine blades can operate is less than it would be otherwise. This limitation significantly decreases the overall process efficiency and lowers the competitiveness of coal as a gas turbine fuel. These and other disadvantages have also prevented lower cost (and abundant) coal from being considered an attractive gas turbine fuel. If a process were developed whereby coal could be burned in a manner that produced hot gases that were not erosive or corrosive, the need for temperature reduction would be eliminated and coal would become a much more economically viable gas turbine fuel.
U.S. Pat. Nos. 5,339,754, 5,509,362, and 5,827,496, disclose a method of burning fuels using a catalyst that is readily reduced when in an oxidized state and readily oxidized when in a reduced state, with the fuel and air being alternatively contacted with the catalyst. The fuel reduces the catalyst and is oxidized to carbon dioxide (CO2) and water vapor. In turn, the air oxidizes the catalyst and becomes depleted of oxygen. Combustion can thereby be effected without the need of mixing the fuel and air prior to or during the combustion process. If means are provided whereby the CO2 and water vapor and the oxygen depleted air can be directed in different directions as they leave the combustion process, the mixing of fuel and air can be completely avoided. This particular method of combustion has become known in the art as “unmixed combustion”.
Hence, there continues to be a need for more efficient, environmentally friendly, reliable power generation process.
Disclosed herein are embodiments of systems and method for using unmixed fuel processors. In one embodiment, a system for using an unmixed fuel processor comprises: an unmixed fuel processor and a power generating unit. The unmixed fuel processor comprises: a gasification reactor, an oxidation reactor and a regeneration reactor. The gasification reactor has a solid hydrocarbon fuel inlet, water inlet, and hydrogen outlet, and comprises a CO2 sorbent material. The oxidation reactor has an air inlet and effluent outlet, and comprises an oxygen transfer material. The regeneration reactor has a CO2 stream outlet and is configured to receive spent CO2 sorbent material from the gasification reactor and to return regenerated CO2 sorbent material to the gasification reactor, and configured to receive oxidized oxygen transfer material from the oxidation reactor and to return reduced oxygen transfer material to the oxidation reactor. The power generating unit configured to receive an oxygen depleted stream from the oxidation reactor and to produce electricity.
In one embodiment, a method for using an unmixed fuel processor comprises: gasifying a solid hydrocarbon fuel with water, capturing CO2 with a CO2 sorbent material to produce a spent CO2 sorbent material and a hydrogen stream comprising hydrogen, oxidizing an oxygen transfer material and producing an oxygen depleted stream in an oxidation reactor, regenerating the spent CO2 sorbent material and the oxidized oxygen transfer material and producing a CO2 stream, and generating electricity in a power generating unit with the oxygen depleted stream.
The above described and other features are exemplified by the following figures and detailed description.
Refer now to the figures, which are exemplary, not limiting, and wherein like numbers are numbered alike.
Integrated gasification combined cycle (IGCC) technology is well suited to better meet the needs for power generation from coal more cleanly than other technologies. It is also compatible with carbon sequestration and production of hydrogen fuel. Also, since unmixed fuel processor (UFP) technology offers the potential for reduced cost, increased process efficiency, and/or lower emissions relative to other gasification and combustion systems, a combination of the combined cycle (CC) and UFP technologies could be improve efficiency in an environmentally friendly fashion. This combined technology could be employed in conjunction with fuel cells and/or with additional plants (e.g., urea and/or ammonia generating plants) to produce electricity, urea, and/or ammonia, while also producing a stream that is ripe for CO2 sequestration.
Referring now to the figures, wherein like elements in the several figures are numbered alike for convenience and clarity of the figures, but are not discussed in relation to each figure.
The UFP technology concept generally uses three circulating fluidized bed reactors containing CO2 sorbent material and oxygen transfer material (OTM). CO2 sorbent material (e.g., metal oxide and/or metal carbonate systems based on elements such as calcium (Ca), magnesium (Mg), sodium (Na), lithium (Li), silicon (Si), as well as combinations comprising at least one of the foregoing) absorbs and/or adsorbs CO2 to form carbonates (sorbent-CO2). The OTM is a metal oxide (e.g., an oxide of iron, nickel, copper, manganese, and so forth, as well as combinations comprising at least one of the foregoing), which can be oxidized to form metal oxides (OTM-O). A mixture of the bed materials is present in each reactor, and the bed materials undergo a variety of transformations and reactions as they move from one reactor to another. Each reactor serves a different key purpose: gasification, CO2 release, or oxidation.
The gasification reactor 28 initially gasifies solid hydrocarbon fuel (e.g., coal and/or other fossil fuels containing elements C, H, O, as well as combinations comprising at least one of the foregoing); coal (e.g., pulverized coal) fed to this is partially gasified with water (e.g., superheated steam) to produce H2, CO, and CO2. Conditions in the gasification reactor (e.g., a temperature of about 600° C. to about 900° C., or, more particularly, about 750° C. to about 850° C.; and a pressure of about 1 atm to about 60 atm, or, more particularly, about 15 atm to about 20 atm) facilitate CO2 absorption by the CO2 sorbent material. The reduction in gas-phase CO2 concentration shifts the equilibrium of the water-gas shift reaction to deplete CO from the gas phase (CO+H2O→H2+CO2). The removal of both CO and CO2 in the gasification reactor 28 results in a H2-rich product stream. The circulation of bed materials provides a continuous supply of fresh CO2 sorbent material from and transfers spent CO2 sorbent material to the regeneration reactor 30.
The regeneration reactor 30 is the location of CO2 release from spent CO2 sorbent material (sorbent-CO2+heat→sorbent+CO2), thereby regenerating the CO2 sorbent. Regeneration occurs as the hot bed material (oxygen transfer material, e.g., at a temperature of about 1,100 to about 1,300° C.) transferred from the oxidation reactor 32 heats regeneration reactor 30, increasing the bed temperature to a sufficient level for CO2 release; e.g., to a temperature of about 900° C. to about 1,100° C. (e.g., at a pressure of about 1 atm to about 20 atm). The CO2 release generates a CO2-rich product stream suitable for sequestration. In addition, the oxidized oxygen transfer material from oxidation reactor 32 is reduced by the sygnas generated from gasification of char as it provides the oxygen needed to oxidize CO to CO2 and H2 to H2O.
OTM-O+CO→OTM+CO2
OTM-O+H2→OTM+H2O
The reduced oxygen transfer material is oxidized in oxidation reactor 32:
OTM+½O2→OTM-O+heat
Hence, air fed to the oxidation reactor 32 re-oxidizes the oxygen transfer material via a highly exothermic reaction that consumes most of the oxygen in the air feed. Thus, the oxidation reactor 32 produces high-temperature (temperature of about 1,100° C. to about 1,300° C.), high-pressure (e.g., a pressure of greater than or equal to about 15 atm, or, more particularly, about 15 atm to about 20 atm) oxygen-depleted (vitiated) air for use in a gas turbine expander, as well as generating heat that is transferred to gasification reactor 28 and regeneration reactor 30, via solid transfer. Essentially, the regeneration reactor 30 exchanges bed materials with both gasification reactor 28 and oxidation reactor 32 with no direct gasification reactor-to-oxidation reactor transfer, thereby allowing for the regeneration and recirculation of both the CO2 sorbent material and the oxygen transfer material. CO2 sorbent material captures CO2 in the gasification reactor 28 and releases it in regeneration reactor 30, while the oxygen transfer material is oxidized in oxidation reactor 32 and reduced in regeneration reactor 30. Other exemplary UTP units that can be used in the systems disclosed herein is disclosed in U.S. patent application Ser. No. ______ to Kulkarni et al., Attorney Docket No. 217323-1 (GE3-0180), filed concurrently herewith.
Referring now to
From the CO2 release reactor 30, reduced oxygen transfer material returns to the oxidation reactor 32, and regenerated CO2 sorbent material passes to the gasification reactor 28, while a CO2 rich stream,r can pass through heat recovery steam generator and condenser 36 and/or through compressor 38 prior to sequestration. The CO2 stream can then be sequestered. Part of the high pressure CO2 stream can be recycled to the CO2 release reactor 30. Recycle of CO2 decreases the steam requirement for fluidization and thus increases the overall efficiency of the process (e.g., an increase in efficiency of greater than or equal to 0.5%, or, even greater than or equal to about 2%).
In the gasification reactor 28, coal is gasified and the CO2 sorbent material captures CO2, facilitating the water gas shift reaction that converts additional CO to CO2 for adsorption and produces a H2 rich stream containing greater than or equal to about 60 volume percent (vol %) H2 in the syngas stream, or, more specifically about 60 vol % to about 90 vol % H2 in the syngas. The CO2 sorbent material returns to the CO2 release reactor 30, while the gasification reactor effluent (a CO2 reduced stream) can pass from the gasification reactor 28, and through a heat recovery steam generator 34, a shift reactor 8, a gas clean-up (e.g., an acid gas recovery (AGR)) unit 10, and pressure swing absorption unit 14. The shift reactor 8 can reduce the concentration of CO in the CO2 reduced stream from about 10 vol % to about 30 vol % down to less than or equal to about 1 vol %, while producing more H2. The acid gas recovery unit 10 removes impurities such as chlorine, sulfur, and ammonia, from the stream (e.g., from the coal-derived syngas). The pressure swing absorption unit 14 further purifies the stream from shift reactor to produce a pure H2 stream (e.g., 99.99% pure) that can be employed, for example, for fuel cell based applications.
The hydrogen stream exiting the PSA unit 14 can be used as desired (e.g., liquefaction, fuel cells, turbines, and so forth), while the PSA off-gas can be compressed in compressor 18 and returned to the oxidation reactor 32 and/or combusted. In other words, all of the PSA off-gas can be recycled to the oxidation reactor 32, or all of the PSA off-gas can be combusted, or, a portion of the PSA off-gas can be recycled to the oxidation reactor 32 while another portion of the PSA off-gas can be combusted. With the recycle of CO2 to the regeneration reactor 30, steam flow to the reactor can be reduced and hence operating costs can be reduced. An effluent stream from the oxidation reactor 32 and/or combustor (see
As noted above and as illustrated in
In
These systems employing power generation with the unmixed fuel processor (UFP) as disclosed herein enable multiple advantages over systems that do not employ the UFP. For example, (i) a fuel cell can be added to the system to further enable electricity generation and/or back-up power generation, an air separation unit is not required as in many power generation systems; (ii) CO2 separation is inherent in the UFP system disclosed; (iii) the hydrogen from the UFP is substantially rich (e.g., greater than or equal to about 80 vol %), thereby reducing the load on the pressure swing absorber; (iv) since a hot oxygen depleted stream can be sent directly to the power generating unit, heat exchange losses are eliminated; (v) the recirculation of the CO2 to the regeneration reactor reduces the amount of steam needed in that reactor, thereby enhancing system efficiency; (vi) the use of the combustor to combust some or all of the PSA off-gas increases inlet temperatures to the expander, again improving system efficiency; and (vii) the hydrogen and nitrogen produced in the system are in a condition that can be used to produce urea and/or ammonia.
Ranges disclosed herein are inclusive and combinable (e.g., ranges of “up to about 25 wt %, or, more specifically, about 5 wt % to about 20 wt %”, is inclusive of the endpoints and all intermediate values of the ranges of “about 5 wt % to about 25 wt %,” etc.). “Combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Furthermore, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The modifier “about” used in connection with a quantity is inclusive of the state value and has the meaning dictated by context, (e.g., includes the degree of error associated with measurement of the particular quantity). The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the colorant(s) includes one or more colorants). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.
All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
This invention was made with Government support under contract number DOE NETL DE-FC26-05NT40974 awarded by the U.S. Department of Energy. The Government may have certain rights in the invention.