Selective Exhaust Gas Recycling in Gas Turbines with CO2 capture: A comprehensive technology assessment

Modern gas turbines operate with large amounts of excess air for cooling and dilution of the combustion gases, in order to maintain gas turbine blade integrity. Selective recycling of CO2 into the gas turbine compressor inlet, also referred as Selective Exhaust Gas Recirculation (SEGR), can reduce the large volumetric flow rate through a CO2 capture system caused by the gas turbine excess air requirements, by 70 - 77%. It also increases CO2 concentrations to 14-18 vol% from 3-4% vol, increasing the driving force for post-combustion capture systems. This paper provides a comprehensive assessment of the concept and presents research outcomes from the UK-funded SELECT project, including power plant and process modelling, techno-economic assessments, pilot-scale gas turbine experimental work and experimental combustion tests on a representative combustor. Using an integrated model of turbomachinery, power cycles and a generic post-combustion CO2 capture technology with a 30%wt MEA solvent, we show that a reduction of up to 50% of the absorber of the capture plant – the most capital intensive part of the process – can be achieved. The compressor and gas turbine operate without any significant deviation from their design point, and a marginal increase of 0.5% point in the net electrical efficiency can be achieved. Pilot-scale testing - conducted at the Pilot Scale Advanced Capture Technologies (PACT) facilities at the University of Sheffield - show that CO2 injection at the compressor inlet of a 100 kW micro gas turbine (mGT) connected to a 1 tonne per day CO2 capture plant reduces net electrical efficiency by 1-2 %point. This is caused by lower flame temperatures, and, unlike in larger gas turbines, the control system of the micro gas turbine. Combustion tests at Cardiff University’s Gas Turbine Research Centre (GTRC) in a pilot-scale high-pressure generic premixed swirl burner, representative of modern dry-low emissions (DLR) gas turbine burners, show the effect of CO2 as diluent on the operational premixed CH4/air flame stability, chemical kinetics and measured exhaust gas composition. CO2 acts as a combustor inhibitor, causing downstream migration of the premixed flame zone, leading to eventual blow-off, instability and extinction, requiring a change in the operation equivalence ratio. The effect of adding CO2 leads to a reduction in the adiabatic flame temperature due to thermal quenching, which results in higher CO emissions and smaller thermal NOx emissions. Increasing pressure has a significant reducing effect on CO emissions, yet it results in higher NOx production, which may require mitigation if this trend is found to continue towards pressures approaching that of the F-class gas turbine. Finally, a conceptual design assessment of a regenerative adsorption wheel with structured adsorbents is proposed for the selective recycling of CO2 in combined cycle gas turbine (CCGT) power plants. It has the advantage of a relatively small pressure drop to reduce the derating of the gas turbine compared to selective CO2 membrane systems. An equilibrium model of a rotary adsorber with commercially available activated carbon adsorbents shows that four rotary wheels of 24 m diameter and 2 m length would be required in an 820MW CCGT plant. A reduction of 50% in the mass of adsorbent would be possible with an adsorbent with a higher capacity, such as Zeolite X13, with upstream dehydration of the flue gases.