CO 2 Absorption Pilot Plant Design, Commissioning, Operational Experience, and Applications Agnes von Garnier, Dr. Andreas Orth and Tobias Stefan, Outotec GmbH Dr. Volker Giesen and Raquel Fernández Rodiles, BASF SE 2 nd International Conference on Energy Process Engineering June 22, 2011
CO 2 scrubbing unit CFB pilot plant Gas cleaning CO 2 scrubbing 2
Outline Objective: demonstration of Circofer process Integration in Circulating Fluidized Bed (CFB) pilot plant Design aspects Commissioning and first operational experience Further plant applications 3
Options for iron and steelmaking Electric steelmaking Oxygen steelmaking Conventional blast furnace Smelting reduction Scrap (+ pig iron) Fine ore Fine ore Lump ore Coal Coal Lump ore Fine ore Fine ore and coal Circored (2 stages) H 2 Pelletizing plant DRI/HBI Natural gas Shaft furnace SL/RN Coke ovens Blast furnace Sinter/ pelletizing plant (HBI) Circofer (1 stage) O 2 Hot DRI and char Air / O 2 Coal AusIron 5 % Hot metal 30 % 65 % O 2 Scrap Hot metal Slag Electric arc furnace (EAF) Oxygen converter (BOF) BOF Steel Steel Steel Pig iron 4
Outotec s direct reduction processes Iron ore Lumps Fines Pretreatment Reductant Coal Gas Process SL/RN Circofer Circored Product Direct reduced iron (DRI) 5
Circofer process flowsheet 6
700 mm CFB pilot plant 7
Integration in CFB pilot plant Operation with H 2 as fluidization gas, open circuit Ore 8
Integration in CFB pilot plant Operation in closed circuit, fluidization with recycling gas Ore compression scrubbing cooling H 2, CO Pilot Pilot plant plant expansion 2009-2010 9
Gas preparation Compression to approx. 5 bar 355 kw liquid ring compressor No temperature increase Decreasing dust load Gas cleaning and cooling New high pressure scrubber (Outotec design) Gas cooler 10
CO 2 absorption pilot plant CO, H 2, N 2 < 1 % CO 2 5 bar 1.3 bar 11
CO 2 absorption pilot plant under construction 12
Commissioning During coal gasification test campaign up to 750 Nm 3 /h tar and dust loaded gas CO 2 removal efficiency > 80 % CO 2 content in incoming gas significantly higher than design Filters succesfully removed solids and tars During Circofer test campaign < 0.5 % CO 2 in recycled gas CO 2 removal efficiency > 95 % 100 Nm 3 /h scrubbed gas recycled to CFB via electrical gas heater additional N 2 added for sufficient fluidization 13
Commissioning during Circofer campaign Typical operational data gas after liquid ring compressor after CO 2 absorption unit temperature C 50 35 pressure kpag 450 440 volume flow Nm³/h 400 300 gas composition (dry) CO 2 %-vol. 13.5 0.3 CO %-vol. 12.1 13.0 H 2 %-vol. 12.2 15.0 CH 4 %-vol. 1.0 0.8 O 2 %-vol. 0.1 0.5 N 2 %-vol. Balance Balance 14
Commissioning during Circofer campaign Typical transient behavior during start-up of CO 2 scrubbing plant 16 14 gas composition / vol% 12 10 8 6 4 2 0 CO CO2 O2 CH4 H2 0 10 20 30 40 50 60 70 time / min 15
Conclusion and further plant capabilities Features CO 2 and H 2 S co-absorption Tars and dust load can be handled Applications Cleaning of process gases from Iron ore direct reduction Coal and biomass gasification Development of Outotec s sustainable energy technologies Reduce carbon footprint coal and biomass based energy production oil winning from oil shale (Enefit process) Carbonate Looping, Oxyfuel Removed gas to be used in other processes for underground storage (CCS) 16