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November 5, 2013
RIST (Research Institute of Industrial Science & Technology)
Progress on CO2 Capture Pilot Plant at RIST
IEAGHG/IETS Iron & Steel Industry CCUS & Process Integration WorkshopDate: 5th to 7th November 2013Tokyo Tech Front, Tokyo Institute of Technology, Japan
1
Contents
History of Aqueous Ammonia-based CO2 Capture Technology
Results of AA-based CO2 Capture Pilot Test
Results of Simulation studies
2013 Pilot Plant Operation Results
2013-2014 Plan
Concept for RIST CO2 Capture Process
2
“Absorption” is a clever choice for the CO2 capture considering the feed gas condition.
Why “Absorption” for CO2 capture?
CO2 concentration (%)
Pre
ssur
e(a
tm)
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
Chemical Absorption-Amine, Ammonia
Chemical Absorption- K2CO3
Physical Absorption-Selexol, Rectisol
Membrane/Adsorption
-PSA
Cryogenic
BFG
Component CO2 CO N2 impurities
BFG (%vol) 20-23 22-25 53-58 Dust, H2S, HCN
Feed gas: BFG, has low heating value (~800kcal/Nm3)- If remove CO2, the heating value of the BFG will increase by approximately 30%
3
Why ammonia-based CO2 capture for iron industry?
▪ Low Corrosiveness : Low construction cost, Easier maintenance, Duration of equipment à Low Capex
▪ Low Chemical Cost : Low operating cost
▪ Low Regeneration Temperature : use waste heats in the iron and steel process
AbsorbentProperty Amines NH3
Absorption Capacity[mol-CO2/mol-absorbent] 0.5 (MEA) 1.0
Regeneration Temp. 120~140 ℃ (MEA) 80-85 oCPrice 1 (MEA) 0.17
Absorbent volatility Low High
Corrosiveness high lowThermal/Oxidative Degradation
(O2, SOx)Severe
(Forms heat stable salts) No degradation
Technical Issues
- Require anticorrosive agent- Higher regeneration temperature- Higher regeneration energy- Health and environmental impacts of amines and their degradation products
- High volatility à Ammonia loss- Slower absorption kinetics
Amines vs. Ammonia
Low Opex
4
Steam from waste heat (120 ℃, 1barg)
RIST NH3 based CO2 capture concept
Process schematics
No additional heat input required from outside !!
5
R&D history
Research milestones• ’06.-: Project initiated • ‘06-’08.: Lab-scale research • June ’09.-June ’10.: 1st stage P/P (50 Nm3/hr, 0.5tCO2/d) operation, CO2 recovery:90%, CO2:>95%• Nov. ’10. - : 2nd stage P/P (1,000 Nm3/hr, 10tCO2/d) operation• May ’12. - : CO2 purification/liquefaction facility operation
§ 1st stage P/P: 50 Nm3/hPOSCO - Pohag Works
CO2 capture
CO2 purification/ liquefaction
§ CO2 capture/purification/liquefaction§ 2nd stage P/P: 1000 Nm3/h
- Liquid CO2 with industrial grade could be produced of at a rate of 3 ton/day since May 2012.- Purity of product L-CO2 ≥ 99.8% (Liquid)
6
Results - waste heat recovery to generate “low pressure steam”
발전소배가스열교환시스템
Low and mid-temp. waste heat recovery system (Closed Loop)
To Reboilers
Waste HeatRecovery
CO2 Capture
▪ Integration of CO2 capture process and waste heat recovery system has been completed.▪ Production of G steam (1 barg at 120℃) using waste heat from boiler stacks▪ Successfully supplied G steam to the CO2 capture pilot facility (10t-CO2/day):
Integration of CO2 capture process and waste heat recovery system
7
Results – technical performances
▪ CO2 removal efficiency ~ 90%
▪ CO2 purity of product stream > 95% (~98%)
▪ Increase of CO content in BFG (~23%à33%) : Heating value increase in BFG
■ Tests w/ pilot facilities• Runs since May 2011 with the current pilot facility
(~ 100 hrs/run)• BFG provided by a slip stream• Ammonia concentration < 10 wt%
▪ Performance - w/ steam generated from waste heat recovery
8
Experimental – test conditions
Major operation variables
Feed Gas: Load of feed gasT/P
Absorbent: Ammonia concentrationFlow rate of circulating absorbent
solution
Wash Water: WW temperatureFlow rates of WW
Others: Types of internalEfficiency of heat exchangersRatio of pump-aroundAddition pump-around
To reduce energy consumption
Time consuming and Too expensive !!
9
A simulation study of the aqueous ammonia CO2 capture process
Feed gas BFG (Blast Furnace Gas)BFG Rate: 1,000Nm3/hrBFG Inlet Temperature: 37℃BFG Inlet Pressure: 650 mmH2OgFeed Gas Composition
Systemconfiguration
Absorber, Regenerator, Concentrator
Ammonia concentration
9 wt%
CO2 recovery 90% (Mole basis)
CO2 con. >95% (Dry & Mole basis)
Component BFG Inlet Conc. (mole fraction)
H2O 0.08
CO2 0.21
N2 0.50
CO 0.21
Process design basis
Absorber Regenerator
Concentrator
Aspen Plus w/ Rate-based model
1010/22
<Absorber> <Regenerator> <Concentrator>
A rate-based simulation model of the ammonia-based CO2 capture process was developed using Aspen Plus 7.3.
The model was adjusted with the experimental results from the pilot plant and validated.
Aspen Plus w/ rate-based model
Parameter study to reduce the thermal energy requirement!
A simulation study of the aqueous ammonia CO2 capture process
11
- Parameters to be considered: Circulating absorbent solution, heat integration, Absorption pressure, Pump around
Parameter study
Circulation
Heat Integration
Pump around
Pressure
Parameter
A simulation study of the aqueous ammonia CO2 capture process
Lean Sol.
12
CO2 capture process parameter study
Regeneration energy reduction estimated by process simulation
Process variables Application plan
1 Absorbent flow rate -
2 Heat exchanger Modified and Tested (2013)
3 Additional pump-around - Absorber Modification scheduled (2014)
4 Lean solution cooling hold
- The regeneration energy was 3.1 GJ/t-CO2 (2012), so it could be reduced considerably.
1313
■ Process modification
§New heat exchanger - New HX: Rich solution-Lean solution)
New HX
[Process modification]
55à65oC
Year 2013 activities
54oC
60oC
New heat exchanger
New blower for higher absorber pressure
1414
Year 2013-14 action plan to reduce regeneration energy
■ Additional pump around - Currently, one PA installed at Absorber - With additional PA, higher CO2 capture capacity- Action plan
~ March ’14.: Construction~ May ‘14.: Performance test
- Continuous long-term operation for 500~1,000 hrs- Scheduled: Oct. ’13. ~ Nov. ‘13 - Evaluate process economics
■ Long-term operation
- Ammonia concentration: 9 wt% (current value to minimize NH3 loss)~ up to 12%
- With higher NH3 concentration, the solvent flowrate could be reduced- Additional regen. energy reduction expected- Scheduled: Oct. ’13. ~
■ Higher NH3 concentration in absorbent solution
15
Scale-UpScale-Up
CommercialCommercialP/PP/P
■ Basic engineering design for commercial scale
§ Major deliverable
- 100X current pilot plant (50MW scale, CO2 Capture 1,000ton/day)
- Process Design Basis & Data
- Process Simulation
- Heat & Material Balance
- Process Flow Diagram (Including Major Control Scheme)
- Utilities & Chemical Consumption
- Equipment List, Equipment Data Sheet
- Piping & Instrument Diagram
- Equipment Location Plan (Plot Plan)
- Material Selection Diagram
- Instrument List with Process Data
- Project Cost Estimation
~ ‘13.11 ’13.11~’14.03
Basic engineering
Basic engineering package
■ Schedule
Contract CAPEX, Plot Plan, Operation Cost
Year 2013-14 action plan