15
1 Slipstream pilot plant demo of a amine-based post- combustion capture technology for CO 2 capture from coal-fired power plant flue gas DOE funding award DE-FE0007453 Krish R. Krishnamurthy, Linde LLC Coal Utilization Research Council 2011 Fall Technical Subcommittee Meeting October 25, 2011, Washington D.C.

Slipstream pilot plant demo of a amine-based post ... Library/Research/Coal/ewr/co2... · — Pilot plant engineering and equipmen t sizing complete for cost assessment (Oct. 31,

Embed Size (px)

Citation preview

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.”

15

Thank you for your attention!

Coal Utilization Research Council2011 Fall Technical Subcommittee MeetingOctober 25, 2011Washington D.C.