CARBON Egypt. "Catalytic N 2 O destruction project in the tail gas of the Nitric Acid Plant of Abu Qir Fertilizer Co UNFCCC 0490

Transcription

1 CARBON Egypt "Catalytic N 2 O destruction project in the tail gas of the Nitric Acid Plant of Abu Qir Fertilizer Co UNFCCC 0490 MENA Carbon Forum 7 th of May 2009 Cairo

2 Content CARBON Egypt Ltd The Clean Development Mechanism (CDM) Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

3 CARBON Egypt CARBON Projektentwicklung GmbH RWE Power AG CARBON EGYPT Ltd. CARBON Egypt Ltd. is a joint venture of: CARBON Projektentwicklung GmbH, Austria and RWE Power AG, Germany; CARBON finances, develops and implements JI/CDM-Projects; Current market share of CARBON is 2,5% on world CDM-Market (expected CERs produced from registered and implemented CDM- Projects until 2012);

4 CARBON s Position in the N 2 O CDM-Market CARBON is a front runner in the N 2 O CDM-business: CARBON has successfully developed and proposed the first N 2 O destruction methodology at nitric acid plants, which has been approved with the CDM EB in March 2006 (AM0028); CARBON operates already the biggest registered CDM-Project in the field of N 2 O destruction at NA-Plants in Africa: Abu Qir Fertilizer Co., Egypt (Nr. 490);

5 Content CARBON Egypt Ltd The Clean Development Mechanism (CDM) Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

6 Flexibility of the Kyoto Protocol Flexible Instruments Emissions Trading Joint Implementation (JI) Clean Development Mechanism (CDM) Joint Implementation Between Annex I Countries (OECD + EE) Eligible between 2008 and 2012 Clean Development Mechanism Between an Annex I Country and a Non-Annex I Country (developing countries and countries in transition) Eligible from now to 2012

7 Project Cycle Clean Development Mechanism Project Identification and Check of CDM or JI-Project Activity s Feasibility Check of host country s project interest & Kyoto status Presentation of the project at Focal Points (Host- and Investor Country) Host country endorsement/approval/no objective Project Design Documents (PDD): Design of Methodology (if necessary) Application for Methodology Approval from CDM EB Validation of PDD by an independent DOE Request of LoA from Host Country (Request of LoA from Investor Country) Request for Project Registration with CDM EB Statement of Modalities for Communication Production of CERs Verification of Monitoring Reports Issuance of CERs from CDM EB Transfer and Payment of CERs

8 Project Cycle CDM EB: Executive Body DOE: Designated Operational Entity PDD: Project Design Document 10 Share of proceeds to the Adaptation Fund 9 Issue of CERs EB 5 Request for Registration 8 Request for issuance of CERs DOE CDM registry 11 transfer of remaining CERs 3 Submission of PDD 6 Submission of monitoring report 4 Validation of PDD 7 Verification and certification of CERs 2 Host Country Approval Host country Investor 1 Request for approval Investor Country

9 Content CARBON Egypt Ltd The Clean Development Mechanism Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

10 N 2 O Destruction Project Abu Qir Fertilizer Co., Egypt Abu Qir Fertilizer Co. is the biggest fertilizer Co in Egypt and the third biggest in the Middle East.

11 N 2 O Destruction Project Abu Qir Fertilizer Co., Egypt Company: Location: Process: Capacity: Tail gas: Abu Qir Fertilizers Co. Alexandria, Egypt Dual Pressure 1,830 t/d HNO3 230,000 Nm3/h Tail gas Temp.: 418 C Start-up on 1st October 2006

12 N 2 O Destruction Project at AFC - Project Description Project Partner: Abu Qir Fertilizer Co., Alexandria, Egypt Abu Qir operates a 1830 MTPD (dual pressure) NA Plant, the biggest NA Plant in the world; Contract between CARBON and AFC has been signed on the 4th and 27th of September 2005; CARBON financed, developed and implemented the CDM-Project at own risk and pays for the total running costs. CARBON EGYPT Ltd. is the owner and seller of the CERs generated; Abu Qir Fertilizer Co. operates the EnviNOx -System together with the nitric acid plant and chemical complex; Host Country has issued a LoNO on April 26, 2005; Host Country has issued a LoA on 1st of June 2006; CDM EB Project Registration on 6th of October 2006; First Issuance of CERs on 31st of May 2007.

13 N 2 O Destruction Project at AFC - N 2 O Abatement I End-of-pipe technology, therefore No contact with product no possibility of product contamination No contact with intermediate product stream no chance of ammonia / NO looses Analogous to established SCR for NOx abatement, promotes acceptance by plant owners Physical space not restricted Highest rates of N 2 O removal possible No compromise necessary between pressure drop and N 2 O destruction lowest pressure drop with highest N 2 O removal Extra space (pipe runs) needed for SRM comparison methods is normally available

14 N 2 O Destruction Project at AFC - N 2 O Abatement II Main components are: Reactor, Mixer, Venturi, Instrumentation Supply lines for NH 3 (and hydrocarbon if needed) Process control system (DCS) Data acquisition and storage equipment CDM Monitoring and Reporting software Advantages of Plug-In Concept: Few interfaces between HNO 3 plant DCS and EnviNOx system Easier to ensure integrity of CDM-relevant operation data Access to CDM monitoring/reporting components can be limited to a few authorized persons manipulations more difficult. Direct generation of CDM Report from DCS minimizes errors and possibility of manipulation.

15 CARBON s N 2 O Projects Measurement Points

16 N 2 O Destruction Project at AFC Measurement Instruments

17 N 2 O Destruction Project at AFC Operator Station (ProPlus)

18 N 2 O Destruction Project at AFC Data storage and access to data Air-Conditioned Container Digital Process Control System (Delta V) Redundant data storage Data Export: Electronic for all raw data, calculated data and reports Access to data: Operator, Maintenance, Administrator (restricted) Automatic generation of reports incl. all CDM relevant data Daily, weekly, monthly and quarterly reports Alarm & Event File Reports

19 Daily Report N 2 O

20 Daily Report NOx

21 N2O percentage removal rate NOx outlet concentration (ppmv) EnviNOx Process 2 (Abu Qir) N 2 O Removal & NOx Outlet Concentration EnviNOx Process (Abu Qir): N 2 O Removal Rate & NOx Outlet Concentration 100% % 96% 94% 92% 90%

22 N 2 O Destruction Project at AFC CER distribution Plant operator AFC Project investor / developer CARBON Egypt EEAA (DNA) Social Fund Donation so far ( ): ~550,000 EUR PDD wording: This fund shall contribute to the social benefit for the people living in the area of the CDM project activity by financing sustainable projects like projects in schools, hospitals and infrastructure. First projects in realization phase

23 Content CARBON Egypt Ltd The Clean Development Mechanism Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

24 Conservative ex-ante Emission Reductions Emission Reductions based on realistic/conservative assumptions Realistic/conservative operating hours of nitric acid plant Realistic/conservative plant output Realistic/conservative N 2 O concentration in the tail gas Ex-ante 1,068,000 CERs/a Issued: ~1,550,000 CERs/a

25 N 2 O Destruction Project at AFC - Realistic Project Size Vintage Year Verification until CERs produced 2006 January 31, , January 31, ,557, January 31, ,567, (forecasts) January 31, ,421, (forecasts) January 31, ,421, (forecasts) January 31, ,421, (forecasts) January 31, ,421,826 Total amount of CERs to sell: 9,228,657 CARBON implements quarterly verification and delivery structure; Conservative PDD expects an annual production of CERs; Past periods outrun the PDD calculation;

26 Content CARBON Egypt Ltd The Clean Development Mechanism Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

27 Challenges during operation Request for Reviews: No reviews, no rejections, no withdrawals Continuous improvement and development of Training for people involved Reporting Maintenance / Emergency services Calibration of instruments Gas analyzer system Spare part stock New Requirements UNFCCC recently issued a new VVM (Validation and Verification Manual) for DOEs DOEs are requested to assess more in detail

28 Content CARBON Egypt Ltd The Clean Development Mechanism Abu Qir N 2 O abatement project Basic Information Conservative ex-ante Emission Reductions Challenges during operation Success Factors

29 Success Factors Quality Assurance I Basic training of operators and maintenance staff by technology provider Additional training with regard to the AMS (Automatic Measuring System) of Egyptian service engineers and external monitoring experts by EMERSON Germany at its factory in Hasselroth (Germany) Permanent quality assurance by the operating staff of AFC Assurance of reliable and correct operation (ISO 9000)

30 Success Factors Quality Assurance II Organization Action Frequency Output Delta V Events & Alarm List Continuously Txt-files, Excel files AFC Shift inspection 3 times a day Plant Check CARBON Egypt Inspection Daily EnviNOx Journal AFC Inspection Weekly AFC Report ENTRAG Health check System diagnostic Monthly Health Check Report on AMS and EnviNOx EMERSON Germany Inspection visit Quarterly Inspection Report on AMS and EnviNOx UHDE Supervision Continuously Plausibility Check EMERSON Germany Supervision Continuously Plausibility Check

31 Success Factors Back Up plans EnviNOx automatic DCS system EnviNOx support Several service contracts in place 24 hours emergency service Spare Parts on stock on-site Comprehensive range of spare part devices on-site Close collaboration with technology provider (AMS) Procedures Immediate response to alarms/malfunctions in the system

32 Success Factors People involved Nitric Acid Plant operator AFC as the foundation of the success Operator Station at AFC control room Visual check 3 times a day Carbon Egypt 3 local engineers 7 day a week coverage by own personnel 2 x chemical engineers 1 x instrumentation engineer Excellent collaboration with EEAA local DNA (Dr Mansour) DNV DOE Technology providers

33

34 CARBON Egypt Ltd. 2 Simon Bolivar Square, Garden City P.O. Box 489, Cairo Egypt Mr. Hani Riskalla Managing Director Mr. Hans-Jürgen Salmhofer Project Manager salmhofer@carbon-austria.com