https://doi.org/10.3390/en15020425
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The estimates of total plant cost (TPC) of the different plant scenarios are presented and compared in Table 7. These results are only for the base cases with ΔTmin of 10 °C. Here and in all other parts of this paper, the FTS-STHX case with ΔTmin of 10 °C is the reference case. The heat exchanger areas used for the heat exchanger purchase costs in this work were estimated based on Equations (1)–(7). In each case, the same type of heat exchanger was specified for the lean/rich heat exchanger, lean MEA cooler and DCC cooler functions, while the UT-STHX was specified for the condenser and condensate cooler.
Table 7. Comparison of the base cases’ total plant costs (TPCs) of the different plant scenarios (reference: FTS-STHX).
| NGCC Power Plant CO2 Capture Processes | Cement Plant CO2 Capture Processes | |||||||
|---|---|---|---|---|---|---|---|---|
| Standard | LVC | Standard | LVC | |||||
| EUR (Millions) | % | EUR (Millions) | % | EUR (Millions) | % | EUR (Millions) | % | |
| FTS-STHX | 172.4 | 0 | 177.9 | 0 | 78.8 | 0 | 85.1 | 0 |
| FH-STHX | 174.5 | 1 | 178.9 | 1 | 79.3 | 1 | 85.7 | 1 |
| UT-STHX | 167.8 | −3 | 174.0 | −2 | – | – | – | |
| PHE | 147.5 | −14 | 160.7 | −10 | 65.2 | −17 | 76.8 | −10 |
Negative percentage indicates cost reduction and positive percentage implies increase in TPC. Comparisons were made with the FTS-STHX in both the NGCC power plant and cement plant processes.
The estimates of the standard CO2 capture processes for the cases of the STHXs systems are close to results in the literature. Manzolini et al. [58] estimated a TPC of an MEA-based standard CO2 capture plant from an NGCC power plant to be EUR 163.2 million in 2015. Li et al. [59] estimated a TPC of USD 132.6 million (2013) for an MEA-based post-combustion CO2 capture from a 650 MWe advanced pulverised coal (APC) power plant. The cost is expected to be lower due to the higher partial pressure of CO2 in an APC power plant exhaust gas. This is in addition to the fact that even the estimated TPCs of similar plants are expected to differ due to the different capital cost estimation methods and underlying assumptions, as well as different plant-specific characteristics [35]. They also used a ΔTmin of 15 °C, which will cause a significant reduction in the capital cost due to a reduction in the cost of the cross-exchanger. It is challenging to make a direct comparison of cost estimates from different studies [35,41,52].
A TPC of EUR 76 million (cost year of 2014) was estimated by [52] for a representative size of a European cement plant with a clinker annual production capacity of 1 metric ton. This study used the Norcem As cement plant in Brevik as a case study, which has an annual cement production of around 1.2 million tons [60].
The results in Table 7 indicate that 14% and 17% can be saved if PHE is specified for the cross-exchanger, lean MEA cooler and DCC cooler functions in the NGCC power plant and cement plant standard CO2 capture processes, respectively. If the lean vapour compression (LVC) configuration is implemented, in both industrial processes, a 10% cost reduction in TPC will be achieved if the PHE is used instead of the FTS-STHX.
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