slipstream pilot plant demo of a amine-based post ... library/research/coal/ewr/co2... · — pilot...
Post on 03-Apr-2018
216 Views
Preview:
TRANSCRIPT
1
Slipstream pilot plant demo of a amine-based post-combustion capture technology for CO2 capture from coal-fired power plant flue gas
DOE funding award DE-FE0007453
Krish R. Krishnamurthy, Linde LLCCoal Utilization Research Council2011 Fall Technical Subcommittee MeetingOctober 25, 2011, Washington D.C.
2
Project Fact Sheet
Scaled-up slipstream Pilot PCC Technology Demonstration — Selected by DOE for funding — Contract sign-off in Oct. 2011— Pilot plant incorporates BASF‘s novel
amine based solvent technology and BASF & Linde process enhancements
Project essentials— Location: 880 MWel Gaston Power plant (operated by Southern Co.) in Wilsonville, AL— Site of the US National Carbon Capture Center— Capacity: Up to 6250 Nm3/h flue gas from coal fired power plant (30 t/d CO2)— CO2 purity 99+ vol % (Dry basis)— Project start: November 2011—Project Duration: 4 years— Partners: Linde LLC, Selas Fluid Processing Corp., Linde Engineering Dresden, BASF, US DOE, EPRI, Southern Company (Host site)— Project Cost: $18.8 million— DOE funding: $15 million
Reco
vere
d CO
2
Deso
rber
Was
te W
ater
FLUE GAS FEED
Abso
rber
Pres
crub
ber
Condenser
Filter*
Reboiler STEAM
CO2-
Lean
Flu
egas
Make-up Water
Interstagecooler
NaOHTank
Solvent Tank
Make Up
Solvent*
NaO
H
Condensate
Provided by Southern/NCCC
(Existing unit)
FLUE GAS RETURN
Make-up
Water
Cooling Water In
CW
CW
CW
CW
CW
To C
W H
X
From
CW
HX
Cooling Water Out
Mak
e-up
Wat
er
Lind
e-BA
SF P
ILO
T PL
ANT
–N
CCC/
Sout
hern
PO
WER
PLA
NT
Inte
rfac
e w
ith T
ie In
Poi
nts
El. Power Supply
Drain*
Reco
vere
d CO
2
Deso
rber
Was
te W
ater
FLUE GAS FEED
Abso
rber
Pres
crub
ber
Condenser
Filter*
Reboiler STEAM
CO2-
Lean
Flu
egas
Make-up Water
Interstagecooler
NaOHTank
Solvent Tank
Make Up
Solvent*
NaO
H
Condensate
Provided by Southern/NCCC
(Existing unit)
FLUE GAS RETURN
Make-up
Water
Cooling Water In
CW
CW
CW
CW
CW
To C
W H
X
From
CW
HX
Cooling Water Out
Mak
e-up
Wat
er
Lind
e-BA
SF P
ILO
T PL
ANT
–N
CCC/
Sout
hern
PO
WER
PLA
NT
Inte
rfac
e w
ith T
ie In
Poi
nts
El. Power Supply
Drain*
3
Overall Objective
— Demonstrate Linde-BASF post combustion capture technology by incorporating BASF’s amine-based solvent process in a 1 MWel slipstream pilot plant and achieving at least 90% capture from a coal-derived flue gas while demonstrating significant progress toward achievement of DOE target of less than 35% increase in levelized cost of electricity (LCOE)
Specific Objectives
— Complete a techno-economic assessment of a 550 MWel power plant incorporating the Linde-BASF post-combustion CO2 capture technology to illustrate the benefits
— Design, build and operate the 1MWel pilot plant at a coal-fired power plant host site providing the flue gas as a slipstream
— Implement parametric tests to demonstrate the achievement of target performance using data analysis
— Implement long duration tests to demonstrate solvent stability and obtain critical data for scale-up and commercial application
Project Objectives
4
CO2 removal rate (90 %)low amine emissions
50 ppm – 2 % CO2
S < 4 – 10 ppm
Treated gas specification
of highest priorityη 7-10% points
not a key issueEnergy efficiency
N2, O2, H2O, CO2, (SOx) NOxCH4, C2H6, …, CO2, H2S, COS, CxHy,S, H2OGas composition
up to 120 mio scf/hrup to 60 mio scf/hrFlowrate
30 – 150 mbars1 – 40 barsCO2 partial pressure
1 bara50 – 100 barsPressure
Flue gasNG/LNG
large volume flows @ low pressuresolvent stability
overall power plant efficiency lossesemissions of solvent
BASF Gas Treatment GroupPost combustion CO2 capture: Challenges compared to CO2 removal in NG/LNG plants
5
Technology Development Path
proof of concept under„synthetic“ conditions
- comparision of solvents- validate simulation models
litmus test for new processunder real conditions
test of complete CCS-chaincapture, compression, transport, storage/EOR
Mini Plant0.015 MWel0.01 mt CO2 / hr
Pilot Plant (Niederaussem*)0.45 MWel0.3 mt CO2 / hr
Demo Plant50 - 250 MMWel34 - 170 mt CO2 / hr
Commercial Plant500 - 1100 MWel340 - 750 mt CO2 / hr
solvent screening- screening methods
Laboratory
Advanced design and new materialsaimed at emissions reductionand capex reduction in the large scale
Pilot Plant (Current)1 - 1.5 MWel0.8 - 1.2 mt CO2 / hr
Safe, reliable, and economicaloperation in compliance withregional and national regulations
Dev
elop
men
tPat
h
Acknowledgement: * Partner and power plant owner/operator: RWE
6
0102030405060708090
1 2 3 4 5 6 7 8 9 10 11 1 2 1 3 14 15 1 6 1 7 1 8 1 9 20 2 1 2 2 2 3 24 25 2 6 2 7 2 8 2 9 30 3 1 3 2 3 3 34 35 3 6 3 7 3 8 3 9 40 4 1 4 2 4 3 44 45 4 6 4 7 4 8 4 9 50 5 1 5 2 5 3 54 55 5 6 5 7 5 8 59 60 6 1 6 2 6 3 6 4 65 6 6 6 7 6 8 69 70 7 1 7 2 7 3 7 4 75 7 6 7 7 7 8 79 80 8 1 8 2 8 3 8 4 85 8 6 8 7 8 8 89 90 9 1 9 2 9 3 9 4 95 9 6 9 7 9 8 99 1 0 0 10 1 10 2 1 03 1 0 4 1 0 5 10 6 1 07 1 08 1 0 9 1 1 0 11 1 11 2 1 13 1 1 4 1 1 5 11 6 11 7 1 18 1 19 1 2 0 12 1 12 2 1 23 1 2 4 1 2 5 12 6 12 7 1 28 1 29 1 3 0 13 1 13 2 1 33 1 3 4 1 3 5 13 6 13 7 1 38 1 39 1 4 0 14 1 1 42 1 43 1 4 4 1 4 5 14 6 14 7 1 48 1 4 9 1 5 0 15 1 1 52 1 53 1 5 4 1 5 5 15 6 15 7 1 58 1 5 9 1 6 0 16 1 1 62 1 63 1 6 4 1 6 5 16 6
screened solvents
cycl
ic c
apac
ity /
Nm
3 /t
MEA
Phase EquilibriaPhase Equilibria KineticsKinetics
0
2
4
6
8
10
12
14
16
18
20
0 10 20 30 40 50 60
Loading
Abs
orpt
ion
rate
MEAtested solvent
Losses/StabilityLosses/Stability
60
70
80
90
100
0 100 200 300 400 500 600time [h]
cont
ent o
f am
ine
tested solvents
MEA
BASF Gas Treatment GroupBASF Gas Treatment Group
Wide range of solvents screened
7
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
8,0
8,5
9,0
0 20 40 60 80 100 120 140 160 180 200circulation rate
spec
. Ene
rgy
Dem
and
MEA optimum
constant feed gas conditions70 % CO2 removal rate
Verification of the screening results
Identification of options for an improved solvent
BASF Gas Treatment GroupBASF Gas Treatment Group
Mini plant – BASF site in Ludwigshafen
8
Niederaussem* pilot plant key results
>90% carbon capture rate achieved
>20% improvement in specific energy compared to MEA
New BASF solvent is very stable compared to MEA
duration of operation
tota
l con
tent
of c
arbo
nic
acid
sMEA
New BASF Development
Acknowledgement: * Pilot project partner RWE
9
Concepts for a Large Scale PCC Plant Key elements of plant costs
Main challenges
— Large equipment size requires new concepts
— Required plot area is very significant
— Alternative materials needs to be assessed
— New equipment arrangements needed
— FIeld fabrication
— Large pipe and duct
Linde studies to address challenges
— Scaling to a very large single train
— Optimize equipment arrangement (flue gas blower, pre-cooler, absorption columns sump etc)
— Develop new column construction materials
— Optimize machinery options
Total plant cost distribution
Engineering and supervision
Equipment incl. columns(w/o blowers & compressors)
Blowers & compressors
Bulk Material
Civil
Construction
10
Project Timeline
Task # TITLE
Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
1 Program Management
Budget Period 1
2 Techno-Economic Evaluation
3 Pilot plant optimization and basic design
4 Pilot plant system design and engineering
5 Pilot plant cost and safety analysis
Go - No GoDECISION
Budget Period 2
6 Supply of plant equipment and materials
7 Plant construction and commissioning
Mechanical completion of pilot plant
Budget Period 3
8 Start-up and initial operation
9 Parametric testing
10 Long duration continuous operation
11 Final economic analysis and commercialization plan
Project Closeout
2012 2013 2014 2015
11
Key Project Milestones
● Budget Period 1 (Nov. 1, 2011 – Jan. 31, 2013)
— Project kick-off meeting with DOE-NETL (11/17/2011)
— 550 MWel power plant with integrated carbon capture techno-economics report (Dec. 31, 2011)
— Optimal design parameters identified and pilot plant design completed (April 30, 2012)
— Host site agreement (Sep. 30, 2012)
— Pilot plant engineering and equipmen t sizing complete for cost assessment (Oct. 31, 2012)
— Development and submission of bid packages (Nov. 30, 2012)
— Completed pilot plant costs based on vendor quotes (Dec. 31, 2012)
● Budget Period 2 (Feb. 1, 2013 – Jan. 31, 2014)
— Pilot plant equipment and modules shop fabrication completed (June 30, 2013)
— Completed ES&H assessment (Dec. 31, 2013)
— Mechanical completion of pilot plant and start-up enabled (Jan. 31, 2014)
● Budget period 3 (Feb. 1, 2014 – Oct. 31, 2015)
— Pilot plant operations validated and ready for testing (April 30, 2014)
— Performance validated against targets (Oct. 31, 2014)
— Long term operability and solvent stability demonstrated (July 31, 2015)
— Technology advantages demonstrated/Ready for commercial (Oct. 31, 2015)
12
Slipstream PCC Pilot Plant: Process Schematic
PC Boiler I II III IV V
Coal AirWater
Steam Turbine
El. Power Generator CO2 Emission
~ 22 TPD / MWe
Ash Flyash
I - NOx Control; II - Air Heater; II - PM Control; IV - Hg Control; V - FGD; VI -
Stack
Solvent regenerationCO2-capture Flue gas cooling, SO2-pre scrubbing
CO2 (20-40) tpd
Desorber
Drain
Flue Gas
(2.4-4.8) MMSCFD
Absorber
Prescrubber
Booster fan
Condenser
Filter
ReboilerSteam (32-64) tpd
CO2-lean flue gas
Make-up water
Interstagecooler
NaOHsolutiontank
Solvent tank
SolventNaOH (optional)
Water
El. Power 12-24 kW
Solvent regenerationCO2-capture Flue gas cooling, SO2-pre scrubbing
CO2 (20-40) tpd
Desorber
Drain
Flue Gas
(2.4-4.8) MMSCFD
Absorber
Prescrubber
Booster fan
Condenser
Filter
ReboilerSteam (32-64) tpd
CO2-lean flue gas
Make-up water
Interstagecooler
NaOHsolutiontank
Solvent tank
SolventNaOH (optional)
Water
El. Power 12-24 kW
LINDE-BASF Pilot Plant
Host Site: 880MWel Gaston coal fired power plant, Wilsonville, AL (managed by Southern Co.). The facilities are part of the National Carbon Capture Center.
Power plant provides:steam for PCC regeneration,cooling water for all HX, and electrical power. Accepts flue gas return after
CO2 capture
Typical coal-fired power plant
Power Plant schematic Source: DOE-NETL FOA ‘403
13
Technical validation to optimize performance and reduce capex and opex for future commercial offering
● Select leading solvent (from development till date) for pilot plant design and planned testing. One potential additional solvent to be considered in 2014 when pilot plant in operation.
● Process testing and validation for lower capex & opex and for emission reduction:
— New absorber construction materials (e.g. Concrete columns with in-liner)
— Advanced absorber structured packing material
— Absorber intercooling without forced recirculation
— Optimized equipment arrangement (blower, sump, intercoolers)
— Advanced stripper design
— Optimized process parameters to reduce steam consumption (e.g. Regeneration pressure)
— Reduced emisson losses through optimized wash system
14
Acknowledgement and Disclaimer
Acknowledgement: This presentation is based on work supported by the Department of Energy under Award Number DE-FE0007453.
Disclaimer: “This presentation was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”
top related