CDR Unit
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satishchemengCommercializing CCS in the EU & Japan MHIs Flue Gas CO2 Capture Technology
12 November 2008
CONTENTS
1. MHIs Commercial Achievements 2. MHIs Long Term 10 t/d CO2 Capture Demonstration Tests from a Coal Fired Boiler 3. MHIs CO2 Recovery Technology 4. Phased Approach to Commercialization for Coal Application 5. Conclusions
1. MHIs Commercial Achievements
MHIs Operating Commercial CO2 Capture Plants
Malaysia
Client: Petoronas Start-up: 1999~ CO2 Source: Nat. Gas Reformer Capacity: 200 t/d Product: Urea
India
Client: IFFCO Location: Aonla Start-up: Dec 2006~ CO2 Source: Nat. Gas Reformer Capacity: 450 t/d Product: Urea
CO2 Recovery (CDR) Plant - IFFCO Aonla Unit (India)
Japan
Client: Chemical Co. Start-up: 2005~ CO2 Source: Nat. Gas Boiler Capacity: 330 t/d Product: General use
CO2 Recovery (CDR) Plant IFFCO Phulpur Unit (India)
India
Client: IFFCO Location: Phulpur Start-up: Dec 2006~ CO2 Source: Nat. Gas Reformer Capacity: 450 t/d Product: Urea
1. MHIs Commercial Achievements
MHIs Recently Awarded Commercial Projects
OTHER PROJECTS
Abu Dhabi
India
Bahrain
Pakistan
Project Status
Under Construction
Under Construction
Under Construction
Under Construction
Flue Gas Source
Nat. Gas. Reformer
Nat. Gas. Reformer
Nat. Gas. Reformer
Nat. Gas. Reformer
Expected on stream
2009
2009
2010
2010
CO2 Capture Capacity (T/D)
400
450
450
340
1. MHIs Commercial Achievements
CO2 Recovery Plant in Malaysia
Plant Outline
CO2 recovery capacity Solvent Use of CO2 Start of operation Client Location Flue gas source : : : : : : : 160T/D (200 T/D Max) KS-1 Urea production October, 1999 Petoronas Fertilizer (Kedah) Sdn Bhd Kedah Darul Aman, Malaysia Stream reformer flue gas
Process Description
CO2 is recovered from flue gas of a steam reformer of on ammonia plant and delivered to CO2 compressor for urea synthesis. Recovered CO2 is used to increase urea production. The first commercial plant for flue gas CO2 recovery using this advanced technology has been operating in Malaysia since October 1999 for Urea production. Performance of the process is excellent in terms of low steam consumption, very low solvent degradation and low solvent loss.
Flue gas CO2 recovery plant (Malaysia)
1. MHIs Commercial Achievements
Commercial Project in Japan
Plant Outline Client Capacity Solvent Feed Gas Use of CO2 : : : : : A Chemical Company 283T/D (330 T/D Max) KS-1 Natural Gas and Heavy Oil Fired Boiler General Use
Process Description CO2 is recovered from a natural gas fired boiler and a heavy oil fired boiler. Flue gas is cooled and SOx is removed (when CO2 is recovered from heavy oil fired boiler) before entering CO2 absorber. CO2 is liquefied and used for dry ice, and weldings.
1. MHIs Commercial Achievements
Commercial Project in India
Plant Outline Client : Solvent : Capacity : Feed Gas : Use of CO2 : Start-up : Indian Farmers Fertilizer Co. KS-1 Solvent 450 T/D x 2 units Natural Gas and Naphtha Reformer Flue Gas Urea Production 2007
Process Description CO2 is recovered from steam reformer flue gases. CO2 is compressed and then used for urea synthesis. Flue gas is cooled and then SOx is removed before entering the CO2 absorber.
CO2 Recovery (CDR) Plant - IFFCO Aonla Unit (India)
2. MHIs long term 10 t/d CO2 capture demonstration tests from a coal fired boiler
Coal Fired Long Term Demonstration Plant
Plant Outline
Solvent : Capacity : Feed Gas : Start-up : Location : KS-1 10 T/D Coal Fired Boiler (14.1 v% CO2) July 2006 Nagasaki, Japan
Operational experiences
Increased understanding of the effects of impurities on the system (dust, SOx, NOx, etc.) Identifying and incorporating countermeasures for each impurity >6,000 hours of operation and experience Test results exceeded expectations and will facilitate scale up CO2 capture for coal fired boilers Confirms that the MHI CO2 capture process can be applied to coal fired flue gas streams
3. MHIs CO2 Recovery Technology
Process Flow for Amine Absorption
Boiler DeNOx Particulate Capture Facility FGD Stack
Flue Gas Outlet
CO2 Purity 99.9 %
Flue Gas
Treated Flue Gas CO2 Capture Compression & Dehydration
CO2 Product
ABSORBER STRIPPER (Regenerator)
C.W.
Flue Gas Cooler/Deep FGD
C.W.
Flue Gas
Pre-treated Flue gas
C.W. Steam
Reboiler
3. MHIs CO2 Recovery Technology
Features
KEPCO & MHIs proprietary Flue gas CO2 capturing Technology Hindered Amine Solvent KS-1 with the special proprietary equipment Proprietary energy efficient process Enables large scale unit by MHIs FGD experiences Advantages
9 KS-1 solvent High CO2 Loading Negligible Corrosion Negligible Solvent Degradation 9 Process Low Utility & Solvent Consumption Easy operation & Maintenance 9 Economy Minimize Operation Costs Scale of Economy by Large Scale Unit
3. MHIs CO2 Recovery Technology
Amine Reaction Mechanism
(Main Reaction)
Mono-ethanol Amine (MEA)
2 R-NH2+CO2
R-NH2 + CO2 + H2O
R-NH3++R-NH-COOR-NH3+ + HCO3-
Sterically Hindered Amine (KS-1) 2 R-NH2 + CO2 R-NH3+ + R-NH-COO-
R-NH2+CO2+H2O
R-NH3++ HCO3-
3. MHIs CO2 Recovery Technology
Large Scale CO2 Capture Plant (3000 T/D Plant)
3. MHIs CO2 Recovery Technology
MHI Heat integration ConceptBase Case)
LP Steam extraction from the LP Turbine Recovery of overhead condenser heat
LP Turbine
HP/MP Turbine Air Heater ESP Boiler
Condenser Regenerator Condenser Deaerator Boiler Feed Water Pump Boiler Feed Water Heater Reboiler
JP Patent No. 207444
Boiler Feed Water Pump
3. MHIs CO2 Recovery Technology
CO2 Recovery Plant Power Output Penalty Assessment and Heat Integration Options;
1) Base Case + 2) Recovery of Compression Heat 3) Recovery of Flue Gas Heat
Power output penalty of CO2 capture and compression without heat integration
1,200
Deep FGD
Net output improvement with heat integration
1200
Power Output Penalty decreased to 20%
1,000
CO2 Recovery Auxillary Equipment
CO2 Compressor Power Loss by LP Steam Extraction
Power Output Penalty by MHI CCCP (Base Case) 22% of Gross Output
1000
Power Output (MW)
800
800 Power Output (MW)
600
400
Net Output + Plant Auxiliary Equipment Power Consumption
600
Power Output Penalty by MHI CCCP Net Output + Plant Auxiliary Equipment Power
400
200
200
CCCP: CO2 Capture, Compression Plant
0 1,070MW (Gross) Supercritical Pulverized Coal Power Plant; Bituminus Coal Case
Without CCCP
With MHI CCCP (Base Case)
With MHI Additional CCCP + Max Heat Integration
3. MHIs CO2 Recovery Technology
Multi-Pollutant Test Plant (FGD & CO2 Capture) Absorber 1 by 1 Scale Test Facility (400 MW equivalent)
Absorber
Spray pipes Fan
32 m
Recirculation Pumps
Commercial Scale Tests Q1 2008 Extensive Liquid Distribution Tests Rectangular Absorber Panel Design
5. Conclusions
Advantages of Post Combustion CO2 Capture
Is applicable for the current, global PC fleet Offers high degree of flexibility is adaptable and cost competitive with other technologies Operation at atmospheric pressure safe and does not require exotic materials Produces highly purified CO2 important environmental consideration for transport and disposal Easy to transfer post combustion technology to developing countries simple process and configuration
Allows for future near zero emission use of fossil fuels
5. Conclusions
Need for Carbon Capture & Storage
Coal will remain a dominant fuel for electric power generation Coal with CCS technology can play an important part in CO2 mitigation Governments must continue to support CCS regulatory certainty and incentives for first stage commercial CCS plants Enhanced Oil Recovery in the short-medium term and Carbon Emission Trading in the medium-longer term can help offset costs associated with CCS
