Development of Mixed-Salt Technology for CO Capture from Coal … · 2015. 9. 11. · Energy and...
Transcript of Development of Mixed-Salt Technology for CO Capture from Coal … · 2015. 9. 11. · Energy and...
Energy and Environment CenterEnergy and Environment Center
3rd Post Combustion Capture Conference (PCCC3)3 Post Combustion Capture Conference (PCCC3)
Development of Mixed-Salt Technology for CO2 Capture from Coal Power Plants
Indira S JayaweeraIndira S. Jayaweera
Sr. Staff Scientist and CO2 Program Leader
SRI I i l
September 8-11 2015 Regina Canada
SRI International
September 8-11, 2015 Regina Canada
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SRI legacy of world-changing innovations
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Technology BackgroundTechnology Background
Energy and Environment Center
Our Early Experience in Solvent-BasedTechnology Development from Proof-of-Concept to Pilot-ScaleEnergy and Environment Center
Ammonia technology development started in 2004
EPRI, NEXANT STATOIL & ALSTOMSTATOIL & ALSTOM
SRI work with multiple clients!
S ll B h S l L B h S lPilot‐Scale (0.25 MWth)
Post‐Combustion CO2 Capture
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Small Bench‐Scale Large Bench‐Scale( )
(For ALSTOM)
Energy and Environment Center
Mixed-Salt Process DetailsEnergy and Environment Center
Key benefits:- Reduced ammonia emissionsReduced ammonia emissions- Enhanced efficiency- Reduced reboiler duty
R d d CO i- Reduced CO2 compression energy
A SIGNIFICANT PARASITIC POWER REDUCTION COMPARED TO MEA !
How it works:Selected composition of potassium carbonate and ammonium salts
O ll h t f ti 35 t 60 kJ/ l (t bl )• Overall heat of reaction 35 to 60 kJ/mol (tunable)Absorber operation at 20 - 40o C at 1 atm with 30-40 wt.% mixture of saltsRegenerator operation at 70 - 180o C at 10-20 atm
• Produce high-pressure CO2 streamProduce high pressure CO2 stream
High CO2 cycling capacity No SolidsHigh CO2 cycling capacity No Solids
5K2CO3–NH3–xCO2–H2O system K2CO3 –NH3–yCO2–H2O systemCO2 Lean CO2 Rich
Energy and Environment Center
Published Data Showing Favorable Kinetics for CO2 Absorption in Ammonia Solutions Energy and Environment Center2 p
Pseudo first-order rate constants for CO2 absorption in NH3, MEA, and MDEA 1.8
2.0
m2 kP
a)
Puxty et al 2010 (6 MWetted wall column data
Solvent kapp/103 s‐1
NH3 at 5°C 0.31.2
1.4
1.6
e (m
mol
/s m
Puxty et al., 2010 (6 M ammonia, 5 C)Dave et al., 2009 ( 7 M ammonia, 5 C)CSIRO, 2012 ( 5 M MEA, 40 C)
NH3 at 10°C 0.7
NH3 at 20°C 1.4
NH3 at 25°C 2.10 4
0.6
0.8
1.0
sorp
tion
Rat
e MEA, 40 C)
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MEA at 25°C 6MDEA at 25°C 0.58Concentration = 1.0 kmol m‐3
0.0
0.2
0.4
0.0 0.2 0.4 0.6 0.8 1.0
CO
2A
bs
Comparison of CO2 absorption rates for MEA and ammonia
Source:Derks and Versteeg (2009). Energy Procedia 1: 1139-1146
CO2 Loading (CO2/NH3 Molar Ratio)
Sources:Dave et al., (2009). Energy Procedia 1(1): 949-954Puxty et al., (2010). Chemical Engineering Science 65: 915-922CSIRO Report (2012). EP116217 SRI small-bench scale data
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Absorber side: Enhanced kinetics
Energy and Environment Center
Mixed-Salt has a Low Energy Requirement for CO2 Stripping Energy and Environment Center2 pp g
High purity CO stream
20 bar
High purity CO2 stream
20 bar
CO2/H2O < 0.02
Estimated regenerator heat requirement for mixed-salt system with 0.2 to 0.6 cyclic CO2 loading. Mixed-salt process requires minimal energy
Sources: MEA data: CSIRO report (2012), EP116217K2CO3 data: GHGT-11; Schoon and Van Straelen (2011), TCCS-6Mixed-salt data; SRI modeling
y y 2 gComparison with neat K2CO3 and MEA is shown. for water stripping
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Mixed salt data; SRI modeling
Regenerator side: Reduced water evaporation
Energy and Environment Center
Mixed-Salt Requires Less Energy for CO2 Compression Energy and Environment CenterCO2 Compression
Amines
80
90
40
50
60
70
t-CO
2
10
20
30
40
kWh/
t
4 3 2 No. of compression stages
Mixed-Salt
0
10
0 2 4 6 8 10 12 14 16 18 20Desorber Pressure (bar)
Electricity output penalty of compression to 100 bar as a function of desorber pressureSource: Luquiaud and Gibbins., Chem Eng Res Des (2011)
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g ( )
CO2 Compression: High-pressure CO2 release
Energy and Environment Center
Mixed-Salt Process Flow DiagramEnergy and Environment Center
Cleaner
>99% CO2
Exhaust
HX4
HX5
K CO richK2CO3 richSalt mixture
HX2NH3 richl
+
REGHX1 HX3
HX2Salt mixture
++++
AB
REGHX1 HX3
Flue Gas
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+
Absorber Regenerator+ +
DOE Project OverviewDOE Project Overview(Large-Bench Scale Testing)Contract No DE FE0012959Contract No. DE-FE0012959
Energy and Environment Center
Project Goals, Team, Duration and BudgetEnergy and Environment Center
Project Duration:30 months Component Testing Component Testing
– Demonstrate the absorber and regenerator processes individually with high efficiency, low NH3emissions, and reduced water use compared to state-of-the-art ammonia-based technologies
Demonstrate the complete CO capture system Demonstrate the complete CO2 capture system– Integrate the absorber and the regenerator – Optimize system operation, and collect data to perform the detailed techno-economic analysis of
CO2-capture process integration to a full-scale power planp p g p p
Conduct the process economic analysis and EH&S analysis
Project Budget :~ $2.29 MProject Budget : $2.29 M
Current Project Team: NETL (Funding Agency and project overseas), SRI International, IHI Corporation, OLI Systems, Stanford University, Dr. Eli Gal, , p , y , y, ,Dr. Kaj Thomsen, and POLIMI
The overall project objective is to demonstrate that mixed-salt technology can capture CO2 at 90% efficiency and regenerate (95% CO2 purity) at a cost of $40/tonne to meet the DOE program goals.
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Absorber and Regenerator SystemsAbsorber and Regenerator Systems
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Absorber InstallationEnergy and Environment Center
Structured packingStructured packing20-ft
Process control& monitoring Column Installation Installed absorber towers13System Commissioned in May 2014
Energy and Environment Center
Schematic and Photograph of the Absorber System Energy and Environment Centery
CO2/Air
Rich out Rich out
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0.25 to 1 t-CO2/day capacity
Energy and Environment CenterRegenerator System
Energy and Environment Center
Li id f dVent line
Liquid feedCO2 product gas
20-f
t
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Results from Component Testing
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Energy and Environment Center
Bench-Scale Absorber PerformanceEnergy and Environment Center
Modeling and Test DataTest Data
CO2 vapor pressure at the absorber exit under various CO2-loading conditions
Better than 90% efficiency with incoming lean absorption solution and < 0.4 CO2 loading
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2 g
The observed overall rates for CO2 absorption are on the same order as those of MEA-based systems and about 5-7x higher than chilled ammonia systems
Energy and Environment Center
Process Ammonia ManagementEnergy and Environment Center
Test Data
ABS 1ABS 1
ABS 1 only ABS2ABS 1 only ABS2
NH3 vapor pressure at the Absorber 1 exit under various CO2-loading conditions
NH3 vapor pressure at the Absorber 1 and 2 exits under various CO2-loading conditions2 2
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Energy and Environment Center
Regenerator Performance Energy and Environment Center
Test Data Modeling and Test Data
Variation of attainable CO2-lean loading level with temperature for rich loadings of
Comparison of measured and modeled attainable CO lean loading at 100 to 150 ºClevel with temperature for rich loadings of
0.40 to 0.50 at 10-12 bar
Process was demonstrated with cyclic loading from 0.2 to (lean) to 0.5 (rich) at 150° C
attainable CO2-lean loading at 100 to 150 ºC.
The produced lean loading well exceeds that required for > 90% CO2 capture from flue gas streams 19
Integrated System Testing
Energy and Environment Center
New Regenerator InstallationEnergy and Environment Center
Single‐stage regenerator used for component testing
21New Dual‐stage regenerator for integrated testing(picture taken on July 2015)
Installed reboiler (picture taken on August 2015)
Energy and Environment Center
Simplified PFD of the Integrated SystemEnergy and Environment Center
1. System is currently in operation with buffer tanks for lean and rich solution storage 2 Continuous operation of the absorber system was smooth and the observed results
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2. Continuous operation of the absorber system was smooth and the observed results were as expected based on the component testing
Energy and Environment Center
System Testing in Continuous ModeEnergy and Environment Center
Test Data Modeling and Test Data
90% CO2 capture efficiency with 0.19 to 0.40 li CO l di i Ab b 1cyclic CO2 loading in Absorber 1
Gas flow rate = 15 acfm
C i f b d dProcess Modeling: SRI (ASPEN) and OLI (ESP) Cyclic Loading = 0 18 to 0 58
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Comparison of observed and modeled temperature profiles for Absorber 1
Cyclic Loading = 0.18 to 0.58Reboiler Duty ~ 1.8 to 1.9 MJ/kg-CO2Ammonia Emission < 10 ppm
Energy and Environment Center
Modeling Results: Preliminary Net Power Efficiency Energy and Environment Centery
Thermodynamic ASPEN Mass & Energy Model Modeling Balance
Software package was developed for thermodynamic modeling of mixed-salt systemsystem
Process layout with two regenerator options were modeled, regenerator
i t i th 1 8energy requirement was in the range 1.8 to 2.2 MJ/kg-CO2, lowest energy option was chosen for the new regenerator designdesign
Next slide shows the summary data from system modeling by OLI (flue t diti i il t DOE C
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stream conditions similar to DOE Case 11)
Mixed-Salt Large Scale System Modeling by OLI: Process Summary
Mole Fraction Flue Gas Feed Stack Gas CO2 Product H2O 0.1537 0.0289 0.0074CO2 0.1350 0.0153 0.9924
99% Purity
Ar 0.0082 0.0110 8.17E‐6N2 0.6793 0.9128 1.84E‐4 NH3 ‐ 9.13E‐6 (6 PPM) 6.93E‐6 (3 PPM) O2 0.0238 0.0320 3.65E‐5 Temperature oC 58 23 56 42 2Temperature, C 58 23.56 42.2Pressure, atm 1.1 1.0 12Flowrate, kgmol/hr 102,548 76,309 12,571 CO2 Capture 90% CO2 Discharge Pressure, atm 12
Reboiler Energy, MJ/KG of CO2 1.97 Reboiler Steam Requirements Cooling Water RequirementsReboiler Steam Requirements Cooling Water RequirementsSteam Source IP Steam Water Source Cooling TowerTemperature, oF (oC) 803.0 (428.3) Temperature, oF (oC) 59 (15) Pressure, psia (atm) 211.9 (14.42) Pressure, psia (atm) 16.2 (1.1) Flowrate, lb/hr (KG/hr) 939,780 (426,277) Flowrate, GPM (m3/hr) 96,092 (21,829)
90% CO2 CaptureSteam/CO2 by weight = <0.9, Cyclic CO2 Loading 0.29 to 0.51
Note: Economic analysis data for the process will be available in Spring 2014
Energy and Environment Center
Mixed-Salt Technology SummaryEnergy and Environment Center
Process Summary• Uses inexpensive industrially available material• Uses inexpensive, industrially available material
(potassium and ammonium salts)• Requires no feedstream polishing
D h d• Does not generate hazardous waste• Has the potential for easy permitting in many localities• Uses known process engineering p g g
Demonstrated Benefits• Enhanced CO2 capture efficiency•
Enhanced CO2 capture efficiency• High CO2-loading capacity• High-pressure release of CO2
E t d B fitExpected Benefits• Reduced energy consumption compared to MEA• Reduced auxiliary electricity loads compared to the
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y ychilled ammonia process
• Possible flexible carbon capture operation
Plans for Future Testing and Commercialization
Energy and Environment Center
Scale-up Plan of Mixed-Salt Process for CO2 Capture from Coal Power Plants Energy and Environment Center2 p
Mixed-salt scale-up timeline proposed by IHI corporationed sa t sca e up t e e p oposed by co po at o
SRI’s Bench-scale System
2013 2015 2020 2025 2030
Pilot PlantPilot Plant1 MW
(Future program)
Validation Stage PlantValidation Stage Plant10-20 MW
Demonstration Plant/Full-scale Plant
100-300 MW
Bench-scale Plant 0.25 to 1 ton-CO2/day (Existing program with DOE)
2828SRI is inviting additional partners for future process scale-up demonstrations
Energy and Environment Center
Current Project LocationEnergy and Environment Center
SRI 6 MW PlantSRI 6 MW Plant
CO2 yard for mini-pilot testing (up to 100 acfm)
S-building: large bench and mini-pilot studies
P-building: lab-scale tests
SRI’s site in Menlo Park, CA (~ 65 acres)SRI also has a test site near Livermore, CA (480 acres) 29
Energy and Environment Center
AcknowledgementsEnergy and Environment Center
NETL (DOE)
• Mr. Steve Mascaro, Ms. Lynn Bricket, and other NETL staff members
SRI Team
• Dr. Indira Jayaweera, Dr. Palitha Jayaweera, Dr. Jianer Bao, Ms. Regina Elmore, Dr. Srinivas Bhamidi, Mr. Bill Olson, Dr Marcy Berding Dr Chris Lantman and Ms Barbara HeydornDr. Marcy Berding, Dr. Chris Lantman, and Ms. Barbara Heydorn
Collaborators
OLI Systems (Dr Prodip Kondu and Dr Andre Anderko) POLIMI• OLI Systems (Dr. Prodip Kondu and Dr. Andre Anderko), POLIMI (Dr. Gianluca Valenti and others), Stanford University (Dr. Adam Brant and Mr. Charles Kang), Dr. Eli Gal, and Dr. Kaj Thomsen
Industrial Partner
• IHI Corporation (Mr. Shiko Nakamura, Mr. Okuno Shinya,
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Dr. Kubota Nabuhiko, Mr. Yuichi Nishiyama, and others)
Energy and Environment Center
DisclaimerEnergy and Environment Center
This presentation includes 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,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 representsinformation, 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 constitutetrademark, manufacturer, or otherwise does not necessarily constitute or imply endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of
h d h i d il fl h fauthors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
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Dr. Marcy [email protected]
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