Consideration in the Engineering and Design of Post-Combustion Capture Technology for Power Plant Application Prachi Singh and Stanley Santos IEA Greenhouse Gas R&D Programme Cheltenham, UK Instituto de Inginieria UNAM 28 th March 2012
Outline of Presentation IEA Greenhouse Gas R&D Programme Post Combustion Capture Technology Global Development Context Absorber and Stripper Columns Solvent Packing Materials Reboilers Steam Extraction ti and Supply Future Development 2
Introduction IEA GREENHOUSE GAS R&D PROGRAMME 3
IEA GHG Introduction IEA Greenhouse Gas R&D Programme (IEA GHG) What is programme s relation to the International Energy Agency (IEA)? What the Programme does? Who are the members? What role do we play in a global CCS context? 4
International Energy Agency The International Energy Agency (IEA) is an intergovernmental organisation which acts as energy policy advisor to 28 member countries in their effort to ensure reliable, affordable and clean energy for their citizens. Founded during the oil crisis of 1973-74, the IEA s initial role was to co-ordinate measures in times of oil supply emergencies. 1 st Implementing Agreement under IEA is the IEA Clean Coal Centre 5
IEA Greenhouse Gas R&D Programme Our Relation to the International Energy Agency IEA GHG is one of 40 organisations having an implementing agreement with IEA 6
IEA Greenhouse Gas R&D Programme A collaborative research programme founded in 1991 as an IEA Implementing Agreement fully financed by its members Aim: Provide members with definitive information on the role that technology can play in reducing greenhouse gas emissions. Scope: All greenhouse gases, all fossil fuels and comparative assessments of technology options. Focus: On CCS in recent years Producing information that is: Objective, trustworthy, independent Policy relevant but NOT policy prescriptive Reviewed by external Expert Reviewers Subject to review of policy implications by Members 7
Members and Sponsors 8
IEAGHG Activities Task 1: Evaluation of technology options Based on a standard methodology to allow direct comparisons and are peer reviewed Task 2: Facilitating implementation Provision i of evidence based information Task 3: Facilitating international cooperation Knowledge transfer from existing, laboratory, pilot and commercial scale CCS projects globally Task 4:To disseminate the results as widely as possible. 9
Specific Area of Focus for CO2 Capture Technology Power Sector o Coal, Natural Gas and Biomass Industrial sectors o Gas production o Oil Refining & Petrochemicals o Cement sector o Iron & Steel Industry Cross cutting issues o Policy/Regulations o Health & Safety o Transport & System Infrastructure 10
Global Policy Context International Policy Setting Implementation actions National/Corporate policy setting National/Corporate research programmes 11
Dissemination GHGT-11 18 th -22 nd Nov. 2012 Kyoto, Japan www.ghgt.info 12
Introduction POST-COMBUSTION CAPTURE IN GLOBAL DEVELOPMENT CONTEXT 13
Post-Combustion Capture Power generation Capture Air N 2, O 2, H 2 O to atmosphere Fuel Boiler or gas Solvent (FGD) turbine scrubbing Steam Steam turbine Power CO 2 compression CO 2 to storage 14
Animated representation of CO 2 removal from natural gas 15
Animated representation of CO 2 removal from flue gas 16
Evolution Coal Fired Flue Gas Application 9 0 <Experience p and R&D Facilities> MHI s Evolution Development of Flue Gas CO 2 Recovery Plant 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 1 Ton/Day Pilot Plant Long Term Demo. Plant 1 Ton/Day Pilot Test Completed Long Term Demo. Plant Test Starts Large Scale Demonstration Plant Design Ready Enlargement 3000 Tonnes /Day Design Completed 6000 Tonnes/Day Design Completes Start of Development Large Scale Test Plant Nanko Pilot Plant (2 Tonnes/day) FGD Experience 3000 Tonnes /Day Plant R&D for Process Improvement Commercial Plant Malaysia kedah Plant 330 Tonnes/day Plant Malaysia Kedah (200 Tonnes/day) Japan, Chemical Company (330 Tonnes/day) India, Fertilizer Company (450 Tonnes/day x 2) Abu Dhabi, Fertilizer Company (400 Tonnes/day) 17
Aker Clean Carbon Technology
Bellingham Power Plant (Flue Gas from Cogeneration Plant) Courtesy of Flour Daniel 19
Bellingham Cogen Plant Massachusetts, USA 350 TPD Liquid CO2 Plant using Econamine FG SM* (proprietary MEA based solvent) CO2 is captured from the flue gas of a gas turbine (a cogen facility) having 14% O2 in the flue gas. Operated by the Suez Energy Generation 20
China s Experience with Post-Combustion Capture Sub -PC Slip stream at Shuanghuai (Chongqing) - Annual Capture: 10,000 t/a CHP Slip stream at Gaobeidian (Beijing) - Annual Capture: 3000 t/a USC PCSlip stream at Shidongkuo (Shanghai) - Annual Capture: 120,000 t/a
Challenges to Post Combustion CO2 Capture Low total flue gas pressure Low CO 2 concentrations Very high flow rates (Huge columns) High energy demand in the reboiler (25-35% of power plant output) Impurities cause solvent degradation, loss of performance and equipment corrosion Solvent losses and waste products Emissions from CO2 capture plant Picture: CASTOR pilot plant Esbjerg 22
Post-Combustion Capture Technology ENGINEERING & DESIGN CONSIDERATION 23
Absorber and Stripper Column Solvent Capacity Loading, Kinetics, Mass Transfer, etc... Packing Column Requires to minimise pressure drop Absorber Stripper designed based on low gas volume 24
Post Combustion Capture Development Process Concept Example Developers Conventional MEA Econamine + Fluor, ABB Ammonia Chilled Ammonia Alstom Hindered Amines KS-1, AMP, MHI, EXXON, Tertiary Amines MDEA BASF, DOW Amino Acid Salts CORAL TNO, Siemens, BASF Potassium Carbonate K 2 CO 3 CO2CRC, Uni Texas Piperazine HiCapt, DMX Mixture IFP Uni Texas Integrated SO 2/CO 2 Amines Cansolv/Shell Amine Aker Clean Carbon Chemical solvents DEAB, KoSol, Calcium based, HTC, Uni Regina, KEPRI, NTNU, SINTEF, CSIRO, KEPRI, EnBW Ionic liquids Adsorbents MOFs, Immobilized amine sorbents, HMS, regenerable sorbents Univ of Leoben NETL, Akermin Membrane Selective, FTM, Module TPS, TNO, NETL, 25
Molecular Structure of Amine C N O C C Monoethanolamine (MEA) C N C N N,N Hexamethylenediamine (HMDA N,N) N ) O C C N C C O Diethanolamine (DEA) Ref: Prachi Singh, 2011 PhD Thesis 26
Steric Hindrance C C N Ethylamine C C C N C Sec-butylamine (α-carbon) C Ref: Prachi Singh, 2011 PhD Thesis O O C C C C N C O C N O Carbamate Functional Group at α-carbon C C C C N N C O C C C O O C Carbamate O 27
Cyclic amine Piperidine (Pd) N H H N Piperazine (Pz) N H H 3 C H N Trans piperazine, 25dimethyl 2,5-dimethyl (2,5 Pz) N H CH 3 28
Structured Packing Design is based on Liquid Loading Capacity Materials Stainless Steel Carbon Steel Aluminium, Hastelloy etc... Suppliers Sultzer (Mellapak) Koch Glitsch (Intalox) etc... 29
Post Combustion Capture Technology AMINE DEGRADATION ISSUE 31
Amine Degradation Issues Solvent Makeup Cost can be significant ifi Operating Cost Environmental implications of amine waste disposal System performance including corrosion and foaming 32
Amine Degradation Oxidative Degradation Thermal Degradation 33
Stripper Column / Reboiler Higher Stripper Temperature gives better reversibility (G. Rochelle) 36
Thermal Degradation Stripper Column / Reboiler / Reclaimer Hexamethylenediamine (HMDA) Ethylenediamine (EDA) Trans, 2,5 Dimethyl Piperazine (2,5 Pz) Piperazine (Pz) Piperidine (Pd) 2-Amino-2-Methyl-1-propanol (AMP) Methylenediethanolamine (MDEA) Diethanolamine (DEA) 3-AminoPropanol (AMP) Monoethanolamine (MEA) Diethyelentriamine (DETA) 0 50 100 150 200 Estimated Stripper Temp. ( C) Data from: Stephanie, 2001, PhD Thesis 37
Post Combustion Capture Technology FOAMING ISSUE 38
Issues with Foaming in Amines Solvent Loss Premature Flooding Reduction in plant throughput Off-specification of products High Solvent Carryover to downstream plants Causes: High Gas Velocity Sludge deposit on gas contractor Process contaminants 39
Parameters affecting Foaming Process Parameters Gas flow rate Solvent Volume Solvent Concentration CO 2 Loading Physical propertiesp Gas density Liquid density Liquid viscosity Surface tension Solvent Temperature 40
Foaming: Effect of Gas Flow Rate Based on Monoethanolamine (MEA) solvent Foaminess coefficient (min): Average Lifetime of Foam Temp:40 C, CO 2 Loading: 0.4 mole CO 2 / mole amine Ref: B. Thitakamol et al. 2008, Ind. Eng. Chem. Res. 47(1), 216-225 41
Foaming: Different Alkanolamine Coeffic cient (m min) Avg g. Foam miness 1 09 0.9 0.8 07 0.7 0.6 05 0.5 0.4 0.3 0.2 0.1 0 MEA solution are easier to have creaming process due to lower solution viscosity. CO2 stripped out during experiment (from 0.4 mol/mol to 0.2 mol/mol) thus increase foaminess MEA DEA MDEA AMP Alkanolamine AMP and DEA is due to high bulk density Ref: B. Thitakamol et al. 2008, Ind. Eng. Chem. Res. 47(1), 216-225 47
Foaming: Effect of Degradation Products Sulphate, Carboxylate, Sulfonate promotes the surface tension reduction therefore increasing the foaming tendency Degradation products Avg. Foaminess Coefficient None 079 0.79 Ammonium Thiosulfate 0.97 Glycolic Acid 094 0.94 Sodium Sulphate, Malonic Acid Oxalic Acid, Sodium Thiosulfate, Sodium Chloride Sodium Thiosulfate, Bicine 0.92 (each) 0.90 (each) 0.85 (each) Hydrochloric Acid, Formic Acid 0.83 (each) Acetic Acid 0.82 Sulphuric Acid 0.77 Ref: B. Thitakamol et al. 2008, Ind. Eng. Chem. Res. 47(1), 216-225 48
Post Combustion Capture Technology STEAM EXTRACTION 49
Impact of Post Combustion to PP Steam Extraction (Source: Bechtel Power) Keeping the Cross Over Pressure to LP Steam Turbine Constant by Throttling Valve 50
Impact of Post Combustion to PP Steam Extraction (Case 2) (Source: Bechtel Power) Variable Back Pressure to LP Steam Turbine (Result: Lower Cross Over Pressure) 51
Impact of Post Combustion to PP Steam Extraction (Case 3) (Source: Bechtel Power) Shut Off Valve to one of the LP Steam Turbine Result: 1 st LP should be larger than 2 nd LP 52
Impact of Post Combustion to PP Steam Extraction (Case 4) (Source: Bechtel Power) Back Pressure Non-Condensing Steam Turbine 53
Penalty to the Steam Turbine Output t 54
Post Combustion Capture Technology CONCLUDING REMARKS 55
Post Combustion: Where to Focus Novel solvents: Higher capacity, lower reaction enthalpy, stable and cheaper Smart process concepts and heat integration Capture environmental impact Cheaper equipments (absorber > 45% of CAPEX) Membranes, adsorbents and other processes have the potential as 2 nd /3 rd generation Source: Figueroa et al., 2008 56
What s Next MHI Large Scale Demo Unit Pilot Plants Nanko Pilot Plant (2t/d) Castor Pilot Plant (2t/d) Commercial Scale Demonstration 57
Thank you Email: Website: stanley.santos@ieaghg.org http://www.ieaghg.org 58