Development of PSA System for the Recovery of

Copyright © 2013 JFE Steel Corporation. All Rights Reserved. 1

Development of PSA Systemfor the Recovery of CO2from Blast Furnace Gas

H.Saima, Y.Mogi, T.HaraokaJFE Steel Corp.

IEA-GHG IETS Iron and Steel Industry Workshop, Tokyo, Japan

Nov. 05 2013

E-mail : [email protected]


Blast Furnace

Blast Furnace

Iron ore

Coke

Hot Air

Fe２O３ + CO → ２Fe + ３CO２

２C + O２ → ２CO

～2,000℃

150～200℃

(Fe2O3)

(C)

Molten Iron(Fe)

Blast Furnace GasCO : 23% CO2 : 22%N2 : 52% H2 : 3%Ambient Pressure ～130kPa

Important Fuel GasMain Origin of CO2

(１,000～1,100℃)


CO2 Emission in Japan

CO2 emission from Steel Works is around 15%Reduction of CO2 is an important subject for Steel Makers

JISF* starts COURSE 50** Project

*JISF : Japan Iron and Steel Federation

186

Japan1,256 Mt(2010)

Steel Works(15%)

COURSE 50 : CO2 Ultimate Reduction of Steel-making Process by InnovativeTechnology for Cool Earth 50

(STEP 1 2008-2012)

CO2 emission in Japan lies around 1.0-1.3 billion tons per year

(STEP 2 2013-2017)


Subjects in COURSE 50

Coke Oven

COG

H2

(H2:50-60%)

Amine

PSA

Separation

CCS?CO2

BFG (CO2:21-23%)

Blast Furnace

Heat RecoverySteam, Power Supply

Our subject

Use of H2 at Blast Furnace for Iron Ore ReductionSeparation of CO2 from BFG with amine or PSARecovery of Wasted Heat to supply separation energy


BlastFurnace

CO2

N2

CO

H2

CO,N2

Inflamable Gas

Fuel Gas

Gas SeparationUnit (PSA)

Adsorbent

for CO2

Adsorbentfor CO

CO2

CO

N2

H2

22%23%

52%

3%

Outline of PSA Project

•CO2 Recovery ≧80% or CO2 Purity ≧90%•Flamable Gas Recovery ≧90%•Reduction of CO2 Recovery Cost >50% (≦2,000yen/t)

Target


Laboratory PSA Apparatus

PSA Tower : ID.40mm x 500mmHx 4 Towers system

Feed Gas : CO2, CO, N2, H2

Each flow rate is controlled independently and mixed.

(Usually use 3towers]


DesorptionRinse

Adsorption Rinse

BFG

N２，CO

CO2

CO2

Vacuum Pump

Press. & Adsorption

Cycle Time

Desorption

3 Steps 3 Towers PSA System


Zeolum F-9H

Active Carbon

CO2 Purity (%)

CO2

Reco

very

(%)

Evaluation by Laboratory PSA

Zeolum F-9H shows high performance in PSA system.Technical target of the project is achieved. (blue area)

Adsorption200kPa*

Desorption7kPa*

*absolutepressure

Cycle Time630sec


Effect of Cycle Time

50

60

70

80

90

96 97 98 99 100

３００sec４５０sec

６３０sec７２０sec

300sec

50

60

70

80

90

96 97 98 99 100

３００sec４５０sec

６３０sec７２０sec

300sec

CO2 Purity (%)

CO2

Reco

very

(%)

No change in performance when cycle time lager than 450 sec.Performance at 300sec is slightly lower but still acceptable.

(Standard)


Effects of CO2 Concentration in Feed Gas

0

2

4

6

8

10

12

14

16

18

20

22% 27% 32% 37%

CO2 Conc. In Raw Gas（％）

CO

2 F

low

Rate

(NL/m

in/kg

)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Ratio o

f C

O2

Flo

w R

ate

(-)

Feed

Recovery

Recovery

Feed

Higher CO2 concentration leads higher recovery rate.

Gas Feed Rate: Constant

CO2 Conc. In Raw Gas(%)


Recovery Cost Estimated from Laboratory Results

Total cost is reduced at shorter cycle time because of lower capital cost and higher CO2 concentration leads more advantage.

-

1,000

2,000

3,000

4,000

Recovery

Cost(

\/t)

630 300 300 Target

Cycle Time (sec)

Cap

ital

Pow

er

High CO2 Conc

Adso

rbent

High CO2 Conc

4,0402,500

2,000


ASCOA‐3* (JFE Steel Fukuyama Area)*Advanced Separation System by Carbon Oxides Adsorption

Start : March 2011

Capacity : 3tons-CO2/dayPlant Area : 21m x 25m


CO2 Adsorption Towers ID : 750mm, Height : 1,200mm


ASCOA‐3 Flow Diagram

ＢＦＧ冷媒

圧縮機ｶﾞｽｸｰﾗｰ脱湿塔脱硫塔

CO2-PSACO2ﾀﾝｸ

中間ﾀﾝｸ真　空ポンプ

中　間ﾌﾞﾛｱｰ

真　空ポンプ

CO-PSACOﾀﾝｸ

混合ﾀﾝｸ

ＢＦＧﾌﾞﾛｱｰ

ﾌﾞﾛｱｰ

ＢＦＧ冷媒

圧縮機ｶﾞｽｸｰﾗｰ脱湿塔脱硫塔

CO2-PSACO2ﾀﾝｸ

中間ﾀﾝｸ真　空ポンプ

中　間ﾌﾞﾛｱｰ

真　空ポンプ

CO-PSACOﾀﾝｸ

混合ﾀﾝｸ

ＢＦＧﾌﾞﾛｱｰ

ﾌﾞﾛｱｰ

Compressor Gas Cooler

Blower

Dehumidifier

Tank

VacuumPump

Tank Blower

Tank TankVacuumPump

DesulfurizingTower

300kPa-abs. 10℃ D.P -60℃


General Test Operation

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

3/8

3/11

3/11

3/14

3/15

3/16

3/17

3/18

3/22

3/23

3/24

CO

2 R

ecove

ry(t

/da

y)

0

10

20

30

40

50

60

70

80

90

100

CO

2 P

urity

, Recove

ry R

atio

(%)

Recover target:3t/day

Purity target:90%

Recovery ratio target 80%

Recovery Ratio

Purity

Achieve 3 targets

Max. Recovery:4.3t/day

Max. Purity:99.5%

Recovery

All technical targets were cleared during test operation period.


Cost Reduction‐Power Consumption of Vacuum Pump‐

3.5

5.2

6.3186

121 123

2

3

4

5

6

7

CO2　22%C.T. 300sec.

CO2 34%C.T. 300sec.

CO2 33%C.T.225sec.

CO

2 R

ecovr

y（t/

Day

）

100

120

140

160

180

200

V.P

um

p P

ow

er

Consu

mpt

ion(k

Whr/

t)

Higher CO2 recovery leads lower power consumption


Further Cost Reduction (Higher Dew Point)

Operation is stable even at a higher dew point.

3

4

5

6

7

8

0 200 400 600 800 1000

Process Time (hr)

CO

2 R

ecove

ry(t

/day

)

(Dew point of raw gas:-60→-30℃)

Gas Pressure : 50kPa CO2 Conc. : 33-34%

5tons/day Condition (Cycle Time : 300sec.)

6tons/day Condition (Cycle Time : 225sec.)


CO2 Adsorption Towers

CenterHalf Radius

Wall Side

11 Resistance Thermometers


0

5

10

15

20

25

30

0 50 100 150 200 250 300

Time/sec.

Tem

pera

ture

/D

egr

ee C

entigr

ade

600h Center 80h Center

600h half radius 80h Half radius

600h Wall side 80h Wall Side

Temperature Distribution(Horizontal Direction)

Gas Outlet

ResistanceThermometer

Gas Inlet

80h

340h

600h

840h

1100h

height/mm

Temperatures at center and half radius move simultaneously


Temperature Distribution

Temperature change indicates adsorption-desorption behavior of CO2

Adsorption-Desorption behaviors at center and half radius are the same.

It is easy to scale-up the adsorption tower to the horizontal direction.

☆

☆

Homogeneity of gas flow in enormous adsorption tower?☆


Pressure Distribution in Commercial Scale Tower

3.76kPa

3.78kPa

Δ0.02

Gas Inlet

kPa

3.76kPa

3.78kPa

Δ0.02

Gas Inlet

kPa

3.76kPa

3.78kPa

Δ0.02

Gas Inlet

kPa 3.25m

11.25m

Pressure difference of lower side of adsorbent layer is only 0.02kPa in a commercial scale adsorption tower.

There are no problems in pressure distribution.

☆

Copyright © 2013 JFE Steel Corporation. All Rights Reserved.

Design of Adsorption Tower

22

17000

1500ID 4000

Adsorbent Layer

Adsorbent : Zeolum F-9HSize : 4,000mmΦ×17,000mm

Adsorption Tower

Weight : 50tonsMaterial : SM490B

Thickness : 12mm

Designed Pressure : 190kPa/FV

Apparent Density : 0.65kg/LWeight : 65tons


Commercial Plant Image (Capacity : 1Mt‐CO2/y)

150ｍ

95m

BeforeDevelopment

After Development1Mt/y

Investment:15B¥200kt/y×5units

Compressor

95m-α

60ｍ

1.26Mｔ/y

500kt/y×2units

Blower (Common)

Vacuum Pump

Investment:7B¥

６．５ｍφ×２３ｍ

Tower

４ｍφ×１７ｍTower

Vacuum Pump


Recovery Cost Estimation

24

Recovery cost was achieved the target! (≦2,000yen/t)

Item

Capital 7,000 Million \

Unit Cost 840 \/t-CO2

Power 145 kWh/t-CO2

Steam 0.05 t/t-CO2

Utility Cost 1,060 \/t-CO2

Adsorbent 390 tons

Unit Cost 40 \/t-CO2

Total Unit Cost 1,940 \/t-CO2

Cost


0

1,000

2,000

3,000

4,000

5,000

Recovery

Cost(

Yen/t-

CO

2)

Initial ASCOA-3 Target

Utility

Capital

Adsorbent

4,040

2,0001,940

25

Cost Estimation from ASCOA‐3 Operation Results

($41/t)

($20/t) ($21/t)


Summery

1. Zeolite type adsorbent has a good performance in Laboratory PSA and ASCOA-3

2. Shorter cycle time and higher CO2 concentration in BFG reduce the cost for CO2 separation

3. The size of commercial adsorption tower was reduced to 1/3～1/4 as the fruit of development

4. CO2 recovery cost achieved the target through the operation result with ASCOA-3 and imaging the design of commercial plant

E-mail : [email protected]

AcknowledgementWe appreciate to NEDO for their financial support.


Thank you for your attention!


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Development of PSA System for the Recovery of