Minimizing Carbon Capture Costs in Power Plants: A Dimensional Analysis Framework for Optimizing Hybrid Post-Combustion Systems

Mitigating greenhouse gas emissions from power plants is crucial for transitioning to a low-carbon economy, necessitating the development of efficient carbon capture, utilization, and storage (CCUS) technologies. CCUS technologies are vital for achieving significant emissions reductions, with post-combustion carbon capture (PCC) emerging as a promising solution. However, high costs and energy penalties hinder its widespread adoption. Recent advancements in hybrid PCC configurations offer improved efficiency and cost reduction, necessitating comprehensive evaluations. This study investigates six feasible hybrid PCC configurations, integrating absorption, absorption, and membrane technologies, to identify the most viable option for CO₂ capture from natural gas power plants (NGPPs). A rigorous techno-economic evaluation is performed using Aspen Hysys design simulation and economic metrics, including investment costs, production costs, net present value, rate of return, levelized cost of electricity, carbon emission intensity, and cost of carbon avoidance. Dimensional analysis reveals the two-stage membrane + absorbent hybrid (2S-MB + AB) configuration as the most promising option. It demonstrates significant cost savings potential, with a 25% reduction in carbon capture costs. Sensitivity analyses highlight the critical role of optimal material selection, specifically membranes, and absorbents, in commercializing this technology. The findings contribute to developing efficient and cost-effective CCUS solutions, aligning with global efforts to mitigate climate change. The recommended 2S-MB + AB configuration offers a promising solution for reducing CO₂ emissions from NGPPs, providing valuable insights for policymakers, industry stakeholders, and researchers. This research informs emissions regulations and incentives for CCUS adoption, guides investment decisions and technology development, and identifies further research and development areas.