Capture of CO 2 from industrial sources Professor Dianne Wiley School of Chemical Engineering, UNSW Australia IEAGHG Summer School 2015 University of Western Australia Perth AUSTRALIA 6-12 December 2015
Industrial CCS is essential Source: Energy Technology Perspectives 2015 Mobilising Innovation to Accelerate Climate Action (2015) IEA 2
Deployment ramp up from 2025 Source: Energy Technology Perspectives 2015 Mobilising Innovation to Accelerate Climate Action (2015) IEA 3
Direct CO 2 emissions (2010) Aluminium 1% Pulp and paper 3% NG Processing 3% Iron & Steel 35% Refining 10% Chemicals 18% Cement 30% Adapted from: Energy Technology Perspectives 2012 Pathways to a Clean Energy System (2012) IEA 4
Emission of CO 2 from industrial processes 5
Major source of CO 2 in industrial processes Chemical reactions that produce CO 2 On-site production of heat or electricity required for production and manufacturing boilers, burners, furnaces 6
World proven natural gas reserves (2011) 100 80 Trillion m 3 60 40 20 0 Africa East Asia Europe LAC MENA North America South & Central Asia SE Asia & Pacific Source: World Energy Council (2013) World Energy Resources: 2013 Survey 7
Natural gas composition Component Chemical Formula Typical range Methane CH 4 70-90% C2-C4 (Ethane, Propane, Butane) C 2 H 6, C 3 H 8, C 4 H 10 0-20% Carbon dioxide CO 2 0-8% Oxygen O 2 0-0.2% Nitrogen N 2 0-5% Hydrogen sulphide H 2 S 0-5% Rare gases Ar, He, Ne, Xe trace Compare coal seam gas (coal bed gas, coal bed methane, coal mine methane) contains CH 4, CO 2, H 2 O little H 2 S, C 2 H 6, C 3 H 8, C 4 H 10 Source: www.naturalgas.org/overview/background.asp 8
Natural gas usage Domestic gas In Australia, CO 2 needs to be reduced to <2% LNG (Liquified Natural Gas) CO 2 <100 ppmv Industrial Gas CO 2 is removed to meet downstream processing and usage requirements 9
Natural gas processing 10
Overview of CCS for natural gas processing CO 2 emissions: centralised separation Attractions: already part of the processing operations Future challenges: high concentration CO 2 fields (up to 80%) sour gas fields 11
Global oil refinery production Source: www.ibtimes.com/articles/85678/20101125/oil-crude-us-dollar-ireland-china-al-naimi-us-fed-eia-oil-price-outlook- 100-mark-70-90-range-oil-tec.htm 12
Some typical crude oil components Source: : www.window.state.tx.us/specialrpt/energy/nonrenewable/crude.php 13
Crude oil refining: one type Source: C&I Engineering, http://www.cieng.com/a-11-156-industries-refining.aspx 14
Crude oil refining: indicative CO 2 emissions Source: C&I Engineering, http://www.cieng.com/a-11-156-industries-refining.aspx 15
Effect of crude quality on CO 2 emissions Source: G. Karas, Oil Refinery CO 2 performance (2011) Communities for a Better Environment 16
Overview of CO 2 capture for oil refineries CO 2 emissions: many distributed locations at variable volumes Attractions: low grade heat available Best opportunities for capture: hydrogen plant o pure CO 2 at atmospheric pressure reformer, catalytic cracker, vacuum distillation o CHP units with CO 2 capture process heaters, furnaces, boilers o similar to power plant compositions 17
Biofuels Solid, liquid or gas fuel derived from biomass Solid: sugarcane bagasse, native grasses, miscanthus, switchgrass, hemp, corn, poplar, willow, sorghum, trees Liquid: bioethanol, biodiesel, aviation fuel Gas: landfill gas, digester gas Source: www.biofuelsassociation.com.au/ 18
Overview of CO 2 capture for biofuels CO 2 emissions: many distributed locations at variable volumes many locations with low to moderate concentration Attractions: low grade heat available energy production from renewable sources 19
Global cement production Source: www.cembureau.be/sites/default/files/productionbyregion2010.pdf 20
Cement production Source: notrickszone.com/2010/07/11/low-energy-cement-production-new-development/ 21
Cement production 0.5 kg CO 2 /kg clinker 22
Challenges of CO 2 capture for cement Flue gas: high CO 2 concentration low SO 2 concentration high temperature relatively low pressure relatively low volume ( 1 Mtpa) Post-combustion capture: low grade heat available no impact on product or process 23
Global steel production Source: www.issb.co.uk/global.html#csp 24
Iron and steel production: major processes 25
Blast furnace: main reactions Source: chemwiki.ucdavis.edu/inorganic_chemistry/descriptive_chemistry/transition_metals_and_coordination_complexes/metallurgy 26
Iron and steel production: full plant Adapted from: Ho, Bustamante, Wiley, Comparison of CO 2 capture economics for iron and steel mills (2013) International Journal of Greenhouse Gas Control, 19: 145-159 27
Challenges of CO 2 capture for iron and steel CO 2 emissions: many distributed locations o low to very low volumes ( 1 Mtpa) major emission at power plant o moderate temperature o low pressure and concentration Nature of steel mills: highly integrated and optimized New processes: blast furnace top-gas recycling increase CO 2 concentration affect heat integration 28
Global ammonia production 100 80 2005 2006 2007 2008 2009 Mtpa 60 40 20 0 North America South America Europe Middle East + Africa Asia Pacific Source: www.indexmundi.com/en/commodities/minerals/nitrogen/nitrogen_t12.html 29
Ammonia production 30
Challenges of CO 2 capture for ammonia production CO2 production and usage: CO 2 separated as pure point source 0.88 tonne CO 2 used per tonne urea CO2 emissions: 1.5 to 3.1 tonne CO 2 per tonne ammonia low temperature high pressure relatively low volume ( 1 Mtpa) 31
Summary: CO 2 concentration in emission gases Source type CO 2 concentration in waste gas (% of dry volume) Pressure of gas stream (kpa) Partial pressure of CO 2 (kpa) Iron blast furnace Up to 27 200-300 before, 100 after combustion 20-60 before, 27 after Cement Kilns 14-33 100 14-33 Ammonia production 18 2800 500 Oil refinery heaters 8 100 8 Natural gas processing 2-65 900-8000 50-4400 Adapted from: IPCC (2005), Special Report on carbon dioxide capture and storage 32
CO 2 capture effort Percent CO2 in flue gas 100 90 80 70 60 50 40 30 20 10 0 Electricity (gas) Required CO 2 concentration for storage Oil refining CAPTURE EFFORT Electricity (coal) Iron and Steel Industrial Process Cement Gas production Source: IPCC (2005), Special Report on carbon dioxide capture and storage 33
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