Reduction of Carbon Dioxide Emissions by Capture and Re-injection

Transcription

1 Reduction of Carbon Dioxide Emissions by Capture and Re-injection Michel Conturie French-Serbian European Summer University Renewable Energy Sources and Environment 17 th 24 th October, 2006 Vrnjacka Banja, Serbia

2 CO 2 and Climate Change Stabilizing emissions will not cope with a stabilization of CO2 concentration and a drastic reduction of CO2 emissions will be necessary. Four directions are today considered to ensure, at the world scale, a significant reduction of these emissions : To reduce the energy wastage To manage better the industrial activity - with reliable emissions figures - by improving energy efficiency To prepare evolution of energy system - with better use of fossil fuels - with carbon-free or renewable energies To imagine and validate efficient capture/storage solutions Source: IPCC SRCCS

3 55% of global CO2 emissions are produced by Industry and Power plants Primary Energy consumption in the World in 2000 : Fossil fuels for 83% of total CO2 Emissions of Industry and Power plants in the World in 2000 : Power, Petroleum, Cement and Steel for 12.5 Gt CO2 i.e. 55% of worldwide total Mtep % C/tep Coal Oil Gas Nuclear [1] Renewable Total Equival. Mt Carbon 6410 corresponding to 23.5 Gt CO2 [1] 1 MWh <=> 0.26 tep CO2 Emissions in % Electricity 59 Petroleum 19 Oil & Gas Production 6 Refining 5 Ethylene & ethylene oxide 3 Hydrogen 2 Ammonia 3 Cement 16 Steel and iron 6 Total Industry 100 Improving energy efficiency in Industry will have a major impact on global CO2 emissions Source IEA, IPCC

4 To manage better the industrial activity with reliable emissions figures Reporting guides, external checking by improving performances - reduction of existing flarings; N2O and HFC reduction - improvement of energy efficiency - sensitivity to a CO2 tax on new projects To establish an european platform of optimisation Foundings, industrial trade center

5 Improvement of energy efficiency in Industry A 3 levels approach, from design of industrial site to its operation : At industrian site and plant level, at the project conception - Platform definition : complementarity / plants interconnection - Utilities selection, thermal integration level At zones and units level - Selection of processes, equipment and integration level At operating level - Adjustment of units (operation parameters) and thermal equipment (burners, furnaces, boilers) Based on an energy referential accessible to all actors (energy efficiency index in reference to an «ideal» operation case)

6 To prepare evolution of energy system with fossil fuels World reserves - Coal to play a significant role (large resources, everywhere, unlike oil and gas) - non conventional oil to take a growing part of oil production - but growing weight of less carbonated natural gas Higher spread of fossil fuels characteristics in the future (Lhv, CO2 emissivity ) Efficient use of these energies in Industry will have a major impact on global CO2 emissions

7 Gasification : a key process for energy conversion Hydrogen will probably be a major energy carrier in the future

8 Primary energy conversion and CO2 emissions Thermal efficiencies of conversion (State-of-the Art) Power generation Boiler + condensation gas turbine : Gas fired : 47% Coal fired : 46% Lignite fired : 43% Natural Gas Combined cycle (NGCC) : 58% Integrated gasification combined cycle (IGCC) : 46% Cogeneration : 60-85% (depending on partial or total LP steam export) Process fluid production Steam : 85% Oxygen : 35% water BFW drum fuel condensate air recovery boiler preheater c.c. steam gas steam air turbine turbine compressor Combined Cycle condenser BFW pump Power loss in transportation : 4 to 6%

9 CCS : Carbon Capture & Storage Capture Transportation Storage Industry & Petrochemical plants Ships EOR / EGR Boilers Power plants Pipelines Trucks Geological storage (saline aquifers, depleted HC reservoirs)

10 CO2 capture and storage : which concepts? Qualifying CO2 sources - Large stationary point sources - High CO2 concentration in the waste, flue gas or by-product stream (purity) - Pressure of CO2 stream - Distance from suitable storage sites Identify significatives storages - Stable sedimentary basins already exploited for HC - Hydrocarbon fields (oil and gas, productive countries), with priority to CO2 EOR and EGR if possible - Saline aquifers (consumer countries) Minimize costs of transportation between capture and storage sites - Pipelines, tankers

11 Large stationary CO 2 point sources 60% of CO 2 emitted by large stationary point sources (more than 0.1 MTCO 2 /year) Capture target : sources > MtCO2/year corresponding to MW th Pci Source: IPCC SRCCS

12 Capture of CO 2 CO2 concentration in the gas source 95-99% v. Boiler, furnace : 8-15% Gas turbine : 3-5% 15-60% 85-95% Source: IPCC SRCCS

13 Energy requirements for capture : Energy efficiency : Loss of overall power plant efficiency as a consequence of CO2 capture Capture efficiency : CO2 emitted / avoided Reference Plant with capture CO2 emitted CO2 avoided CO2 avoided CO2 captured CO2 produced (kg/kwh) - Additional energy use of 10 40% (for( same output) - Capture efficiency:. apparent : 85-95%. effective (net CO2 reduction) ) : 55-90% - Assuming safe storage

14 Potential of GHG geological storage Biomass storage Afforestation Small potential Ocean storage Very weak acceptability 4000 GtC 200% of Emissions to 2050 Liquid denser than water under ~3000 m; CO2 lakes Solid carbonates Underground storage Deep saline aquifers 40 Gt CO 2 <2% of Emissions to Gt CO 2 (including 100 Gt EOR CO2) 45% of emissions to Gt CO % of emissions to 2050 Depleted oil & gas fields Fossil fuels recovery Raw values without consideration of adequation of source localization / potential storage EOR, Enhanced Oil Recovery EGR, Enhanced Gas Recovery ECBMR, Enhanced Coal Bed Methane Recovery

15 Carbon Storage Can sequestration be reliable? What legislation is applicable? What could be the public perception? Risk Management Three major technical issues : CO2 injection CO2 storage capacity Long term CO2 storage Monoun lake, Cameroun, March 2003

16 CO2 capture and storage : which problems? Capture Technically feasible but economically very expansive (~50 /t avoided CO2 or 15 / t C) CO2 gathering and transportation Minimize costs, organize and finance Storage et monitoring Known sedimentary basins, but attention to abandoned wells; > 800 m for supercritical CO2, HC fields or saline aquifers Drilling, compression and monitoring : technical solutions exist, problem of longterm reliability and safety to demonstrate by studies and industrial pilotes

17 CO2 Capture Options - Emission Sources - CO2 capture techniques

18 Mega-boilers for extra-heavy oil hot production Extra-heavy oil : Extra-heavy oil : 9 API High viscosity : 1 res Demineralized water Asphalt Vacuum Residue «petcoke» Combustion + Flue gas Treatment NO X < 200mg/Nm 3 SO X < 200mg/Nm 3 particles < 30mg/Nm 3 CO2 Capture Cold production : not possible hot production with steam Oil flowrate : BPD Steam flowrate : BPD Energy required : 1800 MW» Large flue gas volume to be treated» t CO2 / day to be reinjected Fuel LHV Emissions dry basis MJ/kg t CO2/t g CO2/MJ g CO2/kWh Synthetic crude export Conversion Unit steam CO2 Storage Natural Gas Vacuum residue Asphalt Petcoke Heavy crude Used water to treat Heavy crude / water Steam assisted Heavy crude Production

19 Power generation : State-of of-the Art : Coal-Fired Power Plants Today, capture can reduce the power plants efficiency with 10 to 15%. Ref : Siemens / EFI Conf. May 2006

20 Specification of CO2 Typical gas composition : Usual specification for E.O.R. : Boiler flue gas (petcoke case) 5.5% H2O 75.2% N2 5.1% O2 13.9% CO2 0.3% SO2 Gas Turbine flue gas 7.5% H2O 75.4% N2 13.9% O2 3.2% CO2 MMP = Minimum Miscibility Pressure Specification to reconsider for geological storage - possible CO2 SO2 re-injection

21 Post-capture principle scheme N 2 Vent Off-gas DeNOx Air BOILER Flue gas washing CO 2 Capture Solvent Regeneration Flue Gas (CO 2 ) compression Fuel H 2 O CO2 Capture CO 2 Storage (to treatment ) Chemical solvent at atmospheric P.

22 CO2 capture with MEA Presently referenced as B.A.T. - amine is well-known process (CO2 capture rate, duty) - but working in degraded mode (low P, high O2 content) Uncertainties : - control of corrosion - possible amine concentration - loading rates - amine degradation Potential for future cost reductions : - columns design (diameter, packing) - reboiling ratio - energy integration Energy required : 2 t LP steam/t CO2, i.e. 4 GJ/T CO2 ~ 0.1 tep/t CO2 captured 25 to 35% of combustion energy Capture efficiency : CO2 captured : 90% CO2 released by capture process: 20-30% CO2 avoided : 60-70%

23 Two non post-combustion decarbonisation routes 1. Pre-combustion decarbonisation Air Air Fuel Fuel Conversion CO 2 Separation H 2 Energy Conversion Power CO 2 Flue gas 2. Denitrogenated conversion Air Air Separation O 2 Fuel Energy Conversion Power N 2 CO 2

24 HYDROGEN PRODUCTION GENERATION

25 Oxy-combustion simplified flowsheet Vent N 2 CO 2 recycle Off-gas DeNO x Air Air Separation Unit O 2 BOILER Flue Gas Cooling and Washing Flue Gas Compression Fuel H 2 O (to treatment) CO 2, SO 2 Sequestration

26 Chemical Looping Combustion CO 2 N 2, O 2 Oxidation reactor Me O CO 2, H 2 O Reductio n reactor Compressor Condenser H 2 O Air Interest : Suppression of air compressor Concentrated CO2 flux Me Fuel But : Reactant support to design Experimentation on heavy still to do = High potential on a long period Typical scheme (Lyngfelt et al., Chalmers)

27 CO2 capture & stockage : order of magnitude of costs with the best available technologies : Capture Transportation Storage Capture $/t 1-4 $/t by 100 km 2-8 $/t Compression 8 10 $/t Total = 40 to 80 $/t CO2 based on energy prices in 2003 capture: ~ 2/3 of costs

28 The Oxycombustion route Vent Technologies - Air Separation Unit N 2 CO 2 recycle Off-gas DeNO x - Oxyfuel Boiler - Flue gas treament Air Air Separation Unit O 2 BOILER Flue Gas Cooling and Washing Flue Gas Compression Fuel H 2 O (to treatment) CO 2, SO 2 Sequestration Experimentation on pilot plants -atschwarzepumpein Germany - at Lacq in France

29 Air separation existing technologies For large scale production : Cryogenic Distillation is the most economical with air compression, drying, cooling & distillation Power consumption : At lower scale production Zirconia membranes PSA (pressure swing absorption) systems ~260 kwh/t O2 (MP production) ~220 kwh/t O2 (LP production) Cryogenic Process

30 New technology of oxygen production Oxygen/Ion Transport Membrane (OTM/ITM) for IRCC power plant (Integrated Reforming Combine Cycle) Non porous multi-component ceramic membranes High oxygen flux and high selectivity for oxygen Operate at high temperatures ( C) Can combine air separation and partial oxidation into a single unit operation Source : Air Products Ceramic Autothermal Recovery reactor (CAR) for oxy-fuel combustion

31 Benefits of Oxy-combustion With a recycle rate (~70%) adapted to : Safety Constraint : For an usual air design : O2 content < 25% For an oxygen design : O2 content > 30% Between both : case by case Acceptable thermal flux

32 Oxycombustion flue gas treatment Flue gas composition Specification of CO2 for injection CO2 SO2 co-injection Non condensable gas < 5 % vol. (or 3% wt) for EO.R. Cooling / condensation Treatment scheme to improve Adapted equipment to design Liquid CO2 separation Treatment scheme to improve in consideration of CO2 specification

33 CO2 compression Flue gas condenser 1.0 bar a 45 C Drying unit 75 bar à 45 C purge Refr. 2.9 bar a 45 C 9.4 bar a 45 C 29 bar a 45 C recycle Water treatment unit 85 bar a 33 C 120 bar a ~35 C drain Treatment scheme to improve for a CO2 better separation

34 Liquid CO2 separation Air Products and BP scheme (CCP Project) 29 b 30 C -26 C -55 C Inert gas removal plant using CO2 refrigeration Treatment scheme to improve in consideration of CO2 specification

35 Vattenfall to built pilot plant for a CO 2 free power station The plant will be built next to the Schwarze Pumpe coalfired power station in Brandenbourg (south of Berlin) The pilot will : fire lignite (or coal) with a fuel output of 30 MW use pure O2 and CO2 recycle technology be built in 3 years for a commissioning expected in 2008 with a 2 years test program Budget : 57 M including : - plant investment (37 M ) - test program (20 M )

36 Schwarze Pumpe & Schweinrich Storage Site Baltic Sea Storage site : Schweinrich selected as largest CO 2 storage capacity site 250 km from Schwarze Pumpe BERLIN Schweinrich Schweinrich Lias/Keuper formation Aquifer of 100 km 2 depth of 1700 m, 150 m thick porosity of 28% storage capacity of 1200 Mt CO 2 (for 40% CO 2 water replacement) Schwarze Pumpe Ongoing studies (CO 2 Store) geological modelling (BGR) geochemical modelling (BRGM)

37 Lacq oxy-combustion pilot plant Conversion of air combustion boiler into an oxygen combustion boiler with flue gas recycle. 50 t/h HP (60 bar) steam Boiler (40 MWth) Air heater Fan Fuel gas arrival Flue gas route Combustion air route Steam water

38 Capture and Storage Pilot Plant in Lacq Air Air separation Oxycombustion Flue gas Compression Injection unit Boiler treatment CO 2 /SO 2 LAP (Lacq Profond) Sour crude Vic Bilh CH 4 Fuel Heat/Power Acid water treatment Non cond. gas Demonstration separation loop CO2 Capture CO2 Transport., Injection and Storage The pilot will start in 2008 on gas then sour crude oil (6% S) with a 3-phases program : CO2 capture & injection at 20 bar in Lacq Profond (reservoir still in production) Demonstration of non-condensable gas separation and CO2 liquefaction Injection at high pressure in Rousse (depleted reservoir)