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Co2 Recovery - Iffco

The document provides details about the CO2 removal section of the Ammonia II plant at IFFCO. It uses a dual activator process developed by Giammarco-Vetrocoke (GV) involving absorption of CO2 from the process gas in a hot potassium carbonate solution containing glycine and diethanolamine as activators. The CO2 removal section consists of a single stage absorber and two stage regeneration. In the absorber, CO2 is removed counter-currently using semi-lean and lean solutions. The rich solution is regenerated in a two stage process involving a high pressure first regenerator and a low pressure second regenerator.

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353 views

Co2 Recovery - Iffco

The document provides details about the CO2 removal section of the Ammonia II plant at IFFCO. It uses a dual activator process developed by Giammarco-Vetrocoke (GV) involving absorption of CO2 from the process gas in a hot potassium carbonate solution containing glycine and diethanolamine as activators. The CO2 removal section consists of a single stage absorber and two stage regeneration. In the absorber, CO2 is removed counter-currently using semi-lean and lean solutions. The rich solution is regenerated in a two stage process involving a high pressure first regenerator and a low pressure second regenerator.

Uploaded by

Abizer Jamali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 21

IFFCO

Presented By:
Sanjay Katheria
GET- Chemical

Ammonia II: CO2 Removal Section

12/8/2011

Outline of the Presentation


Introduction
CO2 Removal Processes
CO2 removal section: Ammonia II
o GV Solution
o Absorber
o First Regenerator
o Second Regenerator
Source and References

12/8/2011

Introduction
Carbon dioxide is a gas at standard temperature and pressure and exists
in Earth's atmosphere in this state. CO2 is a trace gas comprising 0.039% of
the atmosphere.

Carbon dioxide is a greenhouse gas as it transmits visible light but


absorbs strongly in the infrared and near-infrared.
General properties:
Colorless
At low concentrations, the gas is odorless. At higher concentrations it has
a sharp, acidic odor.

CO2 is an acidic oxide and toxic in higher concentrations: 1% (10,000


ppm) will make some people feel drowsy. Concentrations of 7% to 10%
cause dizziness, headache, visual and hearing dysfunction, and
unconsciousness within a few minutes to an hour.
3

The triple point of carbon dioxide is about 518 kPa at 56.6 C.

12/8/2011

Industrial production
Industrial carbon dioxide is produced mainly from six processes:
Directly from natural carbon dioxide springs, where it is produced
by the action of acidified water on limestone or dolomite.

As a by-product of hydrogen production plants, where methane is


converted to CO2.
From combustion of fossil fuels and wood.
As a by-product of fermentation of sugar in the brewing of beer,
whisky and other alcoholic beverages.
From thermal decomposition of limestone, CaCO3, in the
manufacture of lime, CaO.
4

12/8/2011

CO2 Removal Process


To purify the synthesis gas and complete the requirement of CO 2 in Urea
Production, CO2 is removed from synthesis gas.

Methods used in CO2 Removal


Amine Gas Treating
Hot Potassium Carbonate Solution Treatment

There are many different amines used in gas treating:


Monoethanolamine (MEA)
Diethanolamine (DEA)
Methyldiethanolamine (MDEA)
Diisopropylamine (DIPA)
Aminoethoxyethanol (diglycolamine) (DGA)
The most commonly used amines in industrial plants are the alkanolamines
MEA, DEA, and MDEA
5

12/8/2011

Contd..
Amines particularly MEA have greater affinity towards CO2 which
results in low exit concentration (from Absorber) of CO2 at relatively
low pressure.
Duel Solvent Methods: Mixture of TEA and MEA

HOCH2CH2NH2 + CO2
HOCH2CH2NHCOO- + H2O

HOCH2CH2NHCOO- + H+
HCO3- + HOCH2CH2NH2

MDEA used with some activator.


MEA Process highly corrosive while MDEA Process requires high
residence time.
6

12/8/2011

Carbonate Solution Process


Amine Gas Treating Process have high regenerative cost.
Hot Potassium Carbonate Solution: Intermediate affinity for CO2
compared to Water and Amines(MEA).
K2CO3 + CO2 + H2O

2KHCO3

Primary and secondary Organic amines, Monoethanol amine


(MEA) and Diethanolamine (DEA) are currently employed alone and
or in combination with hot potassium carbonate solution to catalyse
the CO2 removal Process

12/8/2011

CO2 Removal Section: Ammonia II


Giammarco-Vetrocoke (GV) is a privately-owned company,

located in Venice, Italy.


CO2 removal system of Ammonia II Plant has a conventional
design based on the GV dual activator process. The process
comprises of single stage absorption and two stage
regeneration.
Carbon dioxide is removed by absorption in hot aqueous
potassium carbonate solution containing approximately 30
wt% potash (K2CO3) partly converted into bicarbonate
(KHCO3).

12/8/2011

GV Solution
Dual Activators
Glycine NH2CH2COOH
Diethnolamine NH(CH2CH2OH)
Corrosion Inhibition
V2O5
Composition of fresh solution:
K2CO3/KHCO3
Glycine
DEA
V2O5

27 % w/w
1.2 % w/w
1.0 % w/w
0.4 % w/w

12/8/2011

Chemistry of GV Process
General Reaction
K2CO3 + CO2 + H2O
2KHCO3 + heat
CO2 + H2O
HCO3- + H+ (slow)
CO32- + H2O
HCO3- + OH----------------------------------------------CO32- + CO2 + H2O
2HCO3-

Role of Activator
H2NCH2COO- + CO2

- OOCNHCH COO2

+ H+ (fast)
Glycine Carbamate
-OOCNHCH COO- + H O
H2NCH2COO- + HCO32
2
-----------------------------------------------------------------CO2 + H2O
HCO3- + H+

Hydrolysis of Glycine Carbamate is catalysed by DEA.


10

12/8/2011

Corrosion Inhibition
Acidic nature of solution because of CO2, Carbonic Acid and
Carbamates.

Addition of Vanadium as Corrosion Inhibitor, Static and Dynamic


Passivation (0.5 % V2O5)
Iron content of the solution representation equilibrium (iron
content more than 200-300ppm considered excessively high).
V+5 Protecting Layer( 5-10 % of total vanadium content).
V+5 equilibrium with V+4
V5+ + Fe2+

V4+ + Fe3+
11

12/8/2011

Chemistry of GV Process
Operating Parameters
Temperature
- Hot aqueous solution to increase the rate of reaction.
- Keep the bicarbonate in the dissolved form.
- Boiling point temperature for Regenerators.

Pressure
- High pressure in absorber increase the solubility of process
gas in GV solution
Fractional Conversion (Fc )

K2CO3 + CO2 + H2O


Fc =

2KHCO3

%KHCO3
%K2HCO3 + %KHCO3
12

CO2 Rich Solution

CO2 Rich Solution

Lean
Solution

Process
Gas Outlet

12/8/2011

CO2 at
P = 0.14 Kg/cm2 g

CO2 at
P = 1.1 Kg/cm2 g

Semilean
Solution

Semilean Solution
Steam
Inlet

Process
Gas Inlet
CO2 Rich
Solution

Lean Solution
1st Regenerator

2nd Regenerator

Absorber
13

Process Gas cooled to 104 oC before

Process
Gas Outlet

Lean
Solution

12/8/2011

Absorber

entering into absorber.

Process Gas

Inlet

Outlet

Temperature(oC)

110

71

Pressure(kg/cm2g)

27.9

27.4

Flow Rate(NM3/hr)

312141

203148

% N2

20.75

25.23

% H2

60.74

73.78

% CO

0.12

0.15

% CO2

17.74

0.05

1
4

Process
Gas Inlet

CO2 Rich
Solution
14

2 Stage Process:
- 1st Contact with Semilean Solution
- 2nd Contact with Lean Solution

Semilean
Solution

12/8/2011

Absorber
2 Stage Counter Current Absorption Process:
- 1st Contact with Semilean Solution
- 2nd Contact with Lean Solution
Semi Lean Solution Contact: Lower two beds(3rd & 4th Bed of
Absorber)
About 85% of the total solution
Temperature: 107 oC
Most of the CO2 removed in lower 2 beds(~4000 ppm CO2 left)
Lean solution
Rest 15% of the solution
Temperature: 60oC
CO2 in Process Gas leaving Absorber ~ 500ppm

15

12/8/2011

Absorber Packing
IMTP Packing: Low Pressure drop with high metallic strength w.r.t.
weight.

Volume of the Packing(m3)

Bed

Type

5th Bed(lower)

IMTP 70

11

4th Bed

CMR3 & IMTP 50

105

3rd Bed

IMTP 50 & IMTP 40

105

2nd Bed

IMTP 40

48.5

1st Bed (top)

MELLPACK 250

48.5
16

12/8/2011

First Regenerator
First stage of regeneration process.
Operating Pressure 1.1 kg/cm2g
44% of rich solution extracted from
top tray and send to top of
Vetrocoke
2nd Regenerator.
Process Gas In

Reboiler

CO2 at
P = 1.1 Kg/cm2 g
To 2nd
Regenerator

CO2 Rich Solution

Process Gas out


Semilean Solution

Steam In
Lean Solution
17

12/8/2011

First Regenerator
41% of the semilean solution is taken from lower part of 2nd Bed,
expanded and send to 2nd Regenerator take-off tray.
Remaining strongly regenerated solution expanded and transfer to
bottom of 2nd Regenerator.
Heat Input:
From process gas cooling in two Vetrocoke Reboiler and one LP
Steam Boiler.
LP Steam from ejector.
Operating Condition:
Temperature(oC) (top)

109

Pressure(kg/cm2g) (top/bottom)

1.1/1.3

LP Steam added(kg/hr)

17000
18

2nd stage of stripping at


reduced pressure of 0.14
kg/cm2g.

CO2 at
P = 0.14 Kg/cm2 g

12/8/2011

Second Regenerator
From 1st
Regenerator Top

Semilean Solution from


upper side of take-off tray.
From 2nd Regenerator
second bed bottom

Lean Solution from


bottom of 2nd Regenerator.

Form 1st Regenerator


Bottom

Semilean Solution
P = 0.24 Kg/cm2 g
Take-off
Tray

Lean Solution
P = 0.24 Kg/cm2 g

19

12/8/2011

Regenerators Packing
Mellapack Packing

Regenerator

Volume of the Packing(m3)

Type of Packing

1st Regenerator(HP)

64.0+223.0

IMTP 40 + IMTP 50

2nd Regenerator(LP)

164.0

IMTP 50
20

12/8/2011

Thank You

21

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