CFD investigation of post-combustion CO2 capture using an industrial spray tower: Regulation effects of spray schemes

The use of spray towers for post-combustion CO2 capture has attracted growing industrial interest. However, its practical application is hampered by a lack of knowledge about CO2 spray absorption on an industrial scale. Herein, we developed a numerical model to explore the potential of the spray tower for CO2 removal at a 330 MW coal-fired power plant. The model was developed in the Euler-Lagrange framework integrated with interphase transfer models. The variations of gas-droplet flow, CO2 removal efficiency, CO2 loading of rich solution, and temperature distribution under different spray schemes were investigated. It was found that gas flow hydrodynamics and CO2 removal performance can be regulated by the spray scheme. Compared to the conventional downward spray scheme, the lower nozzle layer adopted an upward spray scheme can improve the uniformity of the gas flow and results in several advantages: (1) average droplet residence time is extended by 5.2 %; (2) CO2 removal efficiency increases from 79.1 % to 82.9 %. This improvement is attributed to two factors: one is the droplet’s re-distribution, lowering the gas flow resistance in the region below the first spray layer near the inlet; the other is the change in gas-droplet interaction whereby the upward-moving droplets entrain the gas to flow upwards. Moreover, we investigated the effects of the spray schemes under varying flue gas loads. Under these conditions, the upward spray mode adopted in the first layer shows the best CO2 removal performance. Further theoretical analysis reveals the mechanisms underlying the regulation effect. The findings in this work will benefit the design and optimization of the industrial-scale spray tower for CO2 removal.