Progress on CO 2 Capture Pilot Plant at RIST

Transcription

1 IEAGHG/IETS Iron & Steel Industry CCUS & Process Integration Workshop Date: 5th to 7th November 2013 Tokyo Tech Front, Tokyo Institute of Technology, Japan Progress on CO 2 Capture Pilot Plant at RIST November 5, 2013 RIST (Research Institute of Industrial Science & Technology)

2 Contents Concept for RIST CO 2 Capture Process History of Aqueous Ammonia-based CO 2 Capture Technology Results of AA-based CO 2 Capture Pilot Test Results of Simulation studies 2013 Pilot Plant Operation Results Plan 1

3 Why Absorption for CO 2 capture? Feed gas: BFG, has low heating value (~800kcal/Nm 3 ) - If remove CO 2, the heating value of the BFG will increase by approximately 30% Component CO 2 CO N 2 impurities BFG (%vol) Dust, H 2 S, HCN 30 Physical Absorption -Selexol, Rectisol Pressure (atm) Chemical Absorption - K 2 CO 3 Chemical Absorption -Amine, Ammonia BFG Membrane/ Adsorption -PSA CO 2 concentration (%) Absorption is a clever choice for the CO 2 capture considering the feed gas condition. 2 Cryogenic

4 Why ammonia-based CO 2 capture for iron industry? Amines vs. Ammonia Property Absorbent Absorption Capacity [mol-co 2 /mol-absorbent] Amines NH (MEA) 1.0 Regeneration Temp. 120~140 (MEA) o C Price 1 (MEA) 0.17 Absorbent volatility Low High Corrosiveness high low Thermal/Oxidative Degradation (O 2, SOx) Technical Issues Severe (Forms heat stable salts) - Require anticorrosive agent - Higher regeneration temperature - Higher regeneration energy - Health and environmental impacts of amines and their degradation products No degradation - High volatility à Ammonia loss - Slower absorption kinetics Low Corrosiveness : Low construction cost, Easier maintenance, Duration of equipment à Low Capex Low Chemical Cost : Low operating cost Low Regeneration Temperature : use waste heats in the iron and steel process Low Opex 3

5 RIST NH 3 based CO 2 capture concept Process schematics Steam from waste heat (120, 1barg) No additional heat input required from outside!! 4

6 R&D history Research milestones 06.-: Project initiated : Lab-scale research June 09.-June 10.: 1 st stage P/P (50 Nm 3 /hr, 0.5tCO 2 /d) operation, CO 2 recovery:90%, CO 2 :>95% Nov : 2 nd stage P/P (1,000 Nm 3 /hr, 10tCO 2 /d) operation May : CO 2 purification/liquefaction facility operation - Liquid CO 2 with industrial grade could be produced of at a rate of 3 ton/day since May Purity of product L-CO % (Liquid) CO 2 capture CO 2 purification/ liquefaction 1 st stage P/P: 50 Nm 3 /h 2 nd stage P/P: 1000 Nm 3 /h 5 POSCO - Pohag Works CO 2 capture/purification/liquefaction

7 Results - waste heat recovery to generate low pressure steam CO 2 Capture 발전소배가스열교환시스템 Waste Heat Recovery Integration of CO 2 capture process and waste heat recovery system To Reboilers Low and mid-temp. waste heat recovery system (Closed Loop) Integration of CO 2 capture process and waste heat recovery system has been completed. Production of G steam (1 barg at 120 ) using waste heat from boiler stacks Successfully supplied G steam to the CO 2 capture pilot facility (10t-CO 2 /day): 6

8 Results technical performances Tests w/ pilot facilities Runs since May 2011 with the current pilot facility (~ 100 hrs/run) BFG provided by a slip stream Ammonia concentration < 10 wt% CO 2 purity of product stream > 95% (~98%) Performance - w/ steam generated from waste heat recovery CO 2 removal efficiency ~ 90% Increase of CO content in BFG (~23%à33%) : Heating value increase in BFG 7

9 Experimental test conditions To reduce energy consumption Major operation variables Feed Gas: Absorbent: solution Load of feed gas T/P Ammonia concentration Flow rate of circulating absorbent Wash Water: WW temperature Flow rates of WW Others: Types of internal Efficiency of heat exchangers Ratio of pump-around Addition pump-around Time consuming and Too expensive!! 8

10 A simulation study of the aqueous ammonia CO 2 capture process Process design basis Feed gas BFG (Blast Furnace Gas) BFG Rate: 1,000Nm3/hr BFG Inlet Temperature: 37 BFG Inlet Pressure: 650 mmh 2 Og Feed Gas Composition Aspen Plus w/ Rate-based model Component BFG Inlet Conc. (mole fraction) H 2 O 0.08 CO N CO 0.21 System configuration Absorber, Regenerator, Concentrator Absorber Regenerator Ammonia concentration CO 2 recovery 9 wt% 90% (Mole basis) Concentrator CO 2 con. >95% (Dry & Mole basis) 9

11 A simulation study of the aqueous ammonia CO 2 capture process Aspen Plus w/ rate-based model A rate-based simulation model of the ammonia-based CO 2 capture process was developed using Aspen Plus 7.3. The model was adjusted with the experimental results from the pilot plant and validated. <Absorber> <Regenerator> <Concentrator> Parameter study to reduce the thermal energy requirement! 10/22 10

12 A simulation study of the aqueous ammonia CO 2 capture process Parameter study - Parameters to be considered : Circulating absorbent solution, heat integration, Absorption pressure, Pump around Parameter Pressure Lean Sol. Pump around Heat Integration Circulation 11

13 CO 2 capture process parameter study Regeneration energy reduction estimated by process simulation Process variables Application plan 1 Absorbent flow rate - 2 Heat exchanger Modified and Tested (2013) 3 Additional pump-around - Absorber Modification scheduled (2014) 4 Lean solution cooling hold - The regeneration energy was 3.1 GJ/t-CO 2 (2012), so it could be reduced considerably. 12

14 Year 2013 activities Process modification New heat exchanger - New HX: Rich solution-lean solution) 60 o C 55à65 54 o C o New HX [Process modification] New heat exchanger New blower for higher absorber pressure 13 13

15 Year action plan to reduce regeneration energy Long-term operation - Continuous long-term operation for 500~1,000 hrs - Scheduled: Oct. 13. ~ Nov Evaluate process economics Higher NH 3 concentration in absorbent solution - Ammonia concentration: 9 wt% (current value to minimize NH 3 loss) ~ up to 12% - With higher NH 3 concentration, the solvent flowrate could be reduced - Additional regen. energy reduction expected - Scheduled: Oct. 13. ~ Additional pump around - Currently, one PA installed at Absorber - With additional PA, higher CO 2 capture capacity - Action plan ~ March 14.: Construction ~ May 14.: Performance test 14 14

16 Year action plan Basic engineering design for commercial scale - 100X current pilot plant (50MW scale, CO 2 Capture 1,000ton/day) Major deliverable - Process Design Basis & Data - Process Simulation - Heat & Material Balance - Process Flow Diagram (Including Major Control Scheme) - Utilities & Chemical Consumption - Equipment List, Equipment Data Sheet - Piping & Instrument Diagram - Equipment Location Plan (Plot Plan) - Material Selection Diagram - Instrument List with Process Data - Project Cost Estimation P/P Scale-Up Commercial Schedule ~ ~ Basic engineering package Contract Basic engineering CAPEX, Plot Plan, Operation Cost 15

17 Thank You!