Condensate System Thermal Integration in Coal Oxy Combustion
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Solution Overview
Problem
Existing coal-fired oxy-combustion steam plants face challenges in integrating thermal sinks such as the Air Separation Unit, Flue Gas Heat Recovery System, Flue Gas Condenser, and Gas Processing Unit into the steam power cycle efficiently, leading to energy wastage and suboptimal thermal efficiency.
Innovation Solution
The integration of these systems into the steam plant condensate system through condensate lines and heat exchangers, forming separate thermal fluid loops that connect the Flue Gas Heat Recovery System and Gas Processing Unit to the condensate system, allowing for flexible operation and improved thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal sinks of the oxy-combustion capture systems are not integrated into the steam power cycle, then the system operation is simpler, but energy is wasted and thermal efficiency is suboptimal
Solution Approach 1:
The patent merges the thermal sinks of the CO2 capture system (Air Separation Unit, Flue Gas Heat Recovery System, Flue Gas Condenser, and Gas Processing Unit) with the steam power cycle by integrating them into the condensate system. This combining of previously separate systems allows heat recovery and utilization that would otherwise be lost, thereby reducing energy wastage while managing the complexity through systematic integration.
Solution Approach 2:
The condensate system is designed to serve multiple functions: it acts as the condensate circulation system for the steam power cycle while simultaneously serving as the thermal integration medium for the CO2 capture system. By making the condensate system universal, it can extract heat from multiple thermal sinks (Air Separation Unit, Flue Gas Heat Recovery System, Flue Gas Condenser, Gas Processing Unit) and transfer it to the steam cycle, reducing energy loss without requiring entirely separate systems.
2Loss of energy
If thermal sinks are integrated into the steam power cycle, then thermal efficiency is improved, but the plant operation becomes less flexible
Solution Approach 1:
The integration design incorporates dynamic control capabilities that allow the system to adjust the degree of thermal integration based on operational requirements. The condensate system can modulate heat transfer rates and flow distributions to accommodate varying plant conditions, maintaining thermal efficiency while preserving operational flexibility through adaptive control mechanisms.
3Use of energy by moving object
If more heat exchangers and thermal integration components are added, then energy recovery is improved, but the device complexity increases
Solution Approach 1:
The condensate system serves as a universal thermal integration medium that simultaneously recovers heat from multiple sources (Air Separation Unit, Flue Gas Heat Recovery System, Flue Gas Condenser, and Gas Processing Unit). By using a single multi-functional system rather than separate dedicated heat recovery systems for each thermal sink, the patent achieves comprehensive energy recovery while limiting the increase in device complexity through systematic design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances overall plant thermal efficiency by optimizing heat management and reducing energy wastage, enabling flexible plant operation while maintaining high CO2 capture efficiency.
Implementation Method 1
The Air Separation Unit has an Air Separation Unit heat exchanger with an Air Separation Unit heat exchanger condensate line connected to the condensate system
Implementation Method 2
The CO2 capture system has a Flue Gas Heat Recovery System... Each of these systems and units may be individually and separately thermally integrated into the condensate system by condensate lines connect to either condensate system heat exchangers
Implementation Method 3
a Flue Gas Condenser and Gas Processing Unit... Flue Gas Condenser... for water removal
Implementation Method 4
a plurality of serial low pressure heaters arranged in flow series numbered starting from one and extending to two, three, four etc, downstream of the pump
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A coal fired Oxy boiler power plant with a condensate system, combustion system and post combustion CO2 capture plant configured and arranged to remove CO2 from a flue gas stream generated in the combustion system. The condensation system includes a plurality of serial low pressure heaters (7, 8, 9, 31) arranged in flow series downstream of the pump (3) and at least one parallel low pressure heater (22) arranged fluidly parallel to at least one of the serial low pressure heaters (7, 8, 9, 31). Flue Gas Heat Recovery System, Flue Gas Condenser and Gas Processing unit are thermally integrated into the condensate system.