International Conference CO 2 Summit: Technology and Opportunity Vail, Colorado - June 6-10, 2010
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1 Greenhouse Gas Capture & Mitigation techniques for different industries AIR LIQUIDE Trapti Chaubey, Paul Terrien, Jean-Pierre Tranier, Rajeev Prabhakar & Aude Delebecque International Conference CO 2 Summit: Technology and Opportunity Vail, Colorado - June 6-10, 2010
2 Air Liquide CO 2 capture activities Clean Coal Power Oxy-Coal Combustion Process Oxy-combustion development Air Separation Unit (ASU) development Agenda CO 2 Compression & Purification Unit (CPU) development Steel Production Ultra Low CO 2 Steel Making (ULCOS) CO 2 capture from Blast Furnace Summary 2
3 Air Liquide Air Liquide (AL), the world leader in gases for industry, health and environment Present in 75 countries 43,000 employees Revenue 12 Billion (2009) > 60% of R&D budget for Sustainable Environment AL involved in CO 2 capture developments for several industries Power Plant Steel Hydrogen poster Iron & Steel Other (4%) Agriculture (2%) Residential (10%) Industry (22%) 6% 4% 6% 6% Chemical & Petrochemicals Non-metallic minerals Others Electricity Generation (39%) Transport (23%) Worldwide CO 2 emissions Breakdown by sector (excluding CO 2 emissions from land use) 3
4 Clean Coal Power 4
5 Three main routes for Clean Coal Power Oxy-combustion 5
6 What is Oxy-Coal Combustion? Oxygen CO 2 Oxygen + Coal CO 2 CO 2 + Coal Nitrogen Nitrogen CO Percent by Volume 100 N 2 O 2 Air H 2 O CO 2 N 2 Flue Gas after WFGD O 2 0 Synthetic Flue Air Gas to CPU Percent by Volume 100 H 2 O H 2 O CO 2 CO 2 Flue gas concentrated in CO 2 6
7 Plant Efficiency No CO 2 Capture 44.6 With CO 2 Capture 2008 Gain 2008 Gain Effic ciency % (HHV) Case 1 SC-Air Case 2 USC-Air DOE AVG IGCC- Air Case 3 SC-Air Post Case 5 B&W/AL SC-Cryo Warm ASU Recycle SC Case 7 SC ITM DOE AVG IGCC Case 4 USC-Air Post Case 6 USC Cryo- ASU B&W/AL Warm Recycle USC References: DOE/NETL Pulverized Coal Oxy-combustion Power Plants Rev.2, DOE/NTL Cost and Baseline for Fossil Energy Plants Rev.1, and B&W/AL Integration Study CO 2 capture from pulverized coal plants is possible with penalty of only ~6 percentage points in efficiency (HHV) 7
8 Levelized Cost of Electricity 14 No CO 2 Capture With CO 2 Capture 2008 Gain 2008 Gain LC COE, /kwh Case 1 SC-Air Case 2 USC-Air DOE AVG IGCC-Air Case 3 SC-Air Post Case 5 SC-Cryo ASU B&W/AL Warm Recycle SC Case 7 SC ITM DOE AVG IGCC Case 4 USC-Air Post Case 6 USC Cryo- ASU B&W/AL Warm Recycle USC References: DOE/NETL Pulverized Coal Oxy-combustion Power Plants Rev.2, DOE/NTL Cost and Baseline for Fossil Energy Plants Rev.1, and B&W/AL Integration Study CO 2 capture from pulverized coal plants is possible with less than 50% increase in cost of electricity 8
9 Clean Coal Development Roadmap O 2 Flue ASU Boiler CPU gas Oxy-combustion development Babcock & Wilcox Air Separation Unit (ASU) development for oxycombustion CO 2 Compression & Purification Unit (CPU) development for CO 2 capture Majority of Oxy-Combustion cost comes from ASU & CPU 9
10 Oxy-combustion development 500 Plant size (MWth) Integration Studies Engg. Study 150 Engg. Studies Demonstration 30 CEDF : first oxy-combustion demo in the world at 30MW scale Callide: Demo of entire oxycombustion system SBS-I 1 SBS-II CEDF Clean Energy Development Facility SBS Small boiler Simulator DOE funded 10
11 ASU optimized for Oxycombustion Cryogenic distillation for O 2 Production More than 100 years of experience AL has built the world s largest ASU Sasol Train (4200 tpd O 2 ) ASU development specifically for oxy-combustion Low purity Oxygen No Nitrogen requirements Separation energy (kwh/ton) NOTE Dark blue represents integration gain Reference line -7.5% T o d a y % w/o integration % w/ integration Pure O2 Year 2000 IGCC Year 2000 OXY LE OXY XLE Target 2015 LE Low Energy, XLE Extra Low Energy.11
12 CO 2 Purification Unit development First Generation CO 2 CPU Offer available Commercial test CO 2 handling (LACQ, France) Successfully started in 2010 CPU in Callide, Australia (Startup in 2011) O 2, N 2, Ar Low Pressure Impurity Treatment High Pressure Impurity Treatment Cold Box (Partial Condensation & Distillation) Compression CO 2 SO x NO 2, HNO 2, HNO 3 H 2 O, Hg NO x Second generation CO 2 CPU in R&D to further reduce cost of capture Improvement in impurities management Improvement in heat integration 12
13 CPU optimization for CO 2 capture Net Specific power of CPU (kwh/t captured CO 2 ) % CO 2 Recovery CO 2 Product Pressure = 175 bar No Purification Cold Box Cold Box and Distillation 95% CO 2 Recovery % CO 2 Recovery 90 70% 75% 80% 85% 90% 95% 100% CO 2 in flue gas ( % mol., dry basis) Process studies to optimize CO 2 recovery and power consumption CO 2 recovery (%) bars a 20 bars a 25 bars a 30 bars a 35 bars a 40 bars a 45 bars a 50 bars a 55 bars a 60 bars a 65 bars a Inlet CO 2 content (mol%, dry basis) 13
14 Industrial Pilot: Callide, Australia Callide, Australia A technological partnership with Callide Oxy-fuel Services, Australia Size: 100 MWth AL will provide 2 ASUs & CPU Near Zero Emission Plant Enable cost reduction and performance improvement for large scale units CPU demonstration based on the down-scale of large unit Start up scheduled
15 STEEL PRODUCTION 15
16 Steel Production - ULCOS 1 ton of steel from integrated steel plant emits almost 2 tons of CO 2 (>60% from Blast Furnace) Continuous growth in Steel demand World-wide Steel Production in 2007 was >1.3 Billion tons Projected 2015 ww Steel Production is 1.8 Billion tons Ultra Low CO 2 Steelmaking (ULCOS) European consortium of Steel Companies and partners 48 members from 15 EU countries ULCOS aims at reducing CO 2 emissions by 50% 16
17 Conventional Blast Furnace Iron Ore Coal Pellet/Sinter Plant Coke Plant Top gas (CO, N 2, CO 2, H 2 ) Coke Oven Off-gas can be used as fuel Coal & Hot Air Blast Ash Removal Pig Iron Top gas contains about 50% N 2 17
18 Sinter, pellets & Coke Top Gas Recycle Blast Furnace Top gas (CO, N 2, CO 2, H 2 ) Gas cleaning system Export gas PSA/VPSA Coal & Hot Air Blast O 2 Blast Full Oxygen Blast Recycle gas heater Recycle Gas CO, H 2 Enriched CO 2 gas Ash Removal Pig Iron CO/H 2 recycling and CO 2 separation for the reduction of CO 2 emissions in blast furnace (BF) 18
19 Industrial Pilot MEFOS, Sweden Air Liquide involved in CO 2 emission reduction from BF CO 2 Separation unit LKAB s experimental BF at MEFOS, Luleå Sweden Top Gas Recycle Blast Furnace (TGR BF) Full Oxygen Blast Max top gas flow rate: 2900 Nm 3 /h Recycle gas injection (CO/H 2 ) Achievements CO 2 VPSA operated reliably as designed Successful tests in Fall 2007 for seven weeks upto 24% in carbon savings Reduction of the CO 2 emissions of up to 76% when assuming underground storage 88% of CO recovery Next Step Industrial size demo ULCOS II 1st world reference for CO 2 capture on top gas recycle BF Start up: Oct 2006 VPSA DESIGNED & BUILT BY AIR LIQUIDE 19
20 Summary Air Liquide is evaluating opportunities for CO 2 capture in many different industrial sectors Power Plant Clean coal oxy-combustion development Optimized ASU with 20% reduced specific energy Optimized CO 2 CPU with flexible design for a range of feed and product specification Overall cost reduction with heat integration of ASU, CPU with steam cycles Steel Production with reduced CO 2 emission TGRBF at MEFOS, Sweden Successful VPSA operation for 7 weeks On-going efforts to identify Industrial Sized Demo Opportunities with industrial and government collaborations 20
21 Acknowledgements Babcock & Wilcox TOTAL Callide Oxy-fuel Services ICCI DOE NETL ULCOS 21
22 THANK YOU 22
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