Optimization of CO2 capture plant through PROII UAS...
Transcript of Optimization of CO2 capture plant through PROII UAS...
Optimization of CO2 capture plant through
Pro-II UAS programming for new solvent
October 6, 2015
Table of Contents
1. Introduction
2. CCS R&D Outline
3. PRO-II UAS programming
4. Future Plan
Daelim Industrial Co., Ltd.Hyun Shin, Ko / General Manager
01 | Introduction
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· Korea’s leading enterprise group
with 76 years’ history
· In the top 100 Korean companies list
since inception 60 years ago
· The first Korean Company operating
in the Middle East
· The first Korean Company to earn
USD by overseas construction work
· Ranked 18th in Korea’s business
groups
· Implements projects in 35 countries
· Korea’s leading construction/
petrochemical group
· Listed in the DJSI World Index
in 2013, 2014
· Seeks to be a global developer
for petrochemical and
power generation sectors based
on global top-tier EPC
capabilities
Global
Developer
Overview
Daelim Group
Since
1939
USD 16.4 Billion
in Asset Size
of 14 Affiliates
Founded in 1939, the Daelim Group is Korea's representative group composed of
14 affiliates including power generation, logistics, manufacturing and IT companies,
based on Daelim Industrial, a global EPC contractor and Petrochemicals company.
01 | Introduction
3
Plant Petro-
chemical
Unit
Civil
Engineering
Building
& Housing
Yeochun
NCC
(YNCC)
PolyMirae
(PMC)
KRCC
Daelim Industrial Co., Ltd.
Engineering &
Construction Unit
Petrochemical
Unit
Daelim Corporation
Daelim C&S
Daelim Motor Co., Ltd.
Trading &
Manufacturing
Daelim EnergyEnergy
Korea Development
Corporation
Samho International
Construction
Daelim University
College
Daelim Contemporary
Art Museum
Education &
Culture
Daelim I&SInformation
Technology
Ora Resort Co., Ltd.Leisure Service
BusinessPortfolio
Daelim Group
Group
01 | Introduction
4Singori Nuclear Power PlantSahara PDH, Saudi Petron RMP-2 Refinery, Philippines
Overview
Highlights
· World’s largest polycarbonate plant (260,000MTPA,
Kayan Polycarbonate, Saudi, ’2007~’2010)
· World’s largest PDH plant (PDH 467,000MTPA, PP
450,000MTPA , SAHARA AI-Waha PDH/PP, Saudi, ’2006~’2008)
· Awarded Saudi SABIC's Best Project in 2008
(Ibn Zahr PP III U&O Project, Saudi, ‘2006~‘2008)
· The largest project award in Korea within South East
Asia region (Petron RMP-2 Refinery Project, USD 19.8
billion, Philippines, ’2010~’2014)
· Four Petrochemical units invested by US oil major
Chevron Phillips (NCP Polymer Project, Saudi, ’2007~’2011)
· The first Butanol Plant in Saudi Arabia and the largest in
the world (SABUCO Butanol & Syngas Project, ’2013~’2015)
· The largest Refinery Expansion Project in Oman
(Sohar Refinery Improvement Project, ’2013~’2016)
Plant
· More than 600 projects completed or underway in 36 countries
· 40 years’ skilled and sophisticated design competencies
with adoption of advanced engineering in 1974
· Total service offered including FEED (Front End Engineering
Design ), EPC (Engineering Procurement Construction) and
O&M (Operating and Maintenance)
· O&M competency secured through petrochemical
plant operations (Petrochemical Business Division built up
know-how on plant operations for more than 30 years)
· The most number of bids invited by major clients in
the Middle East (80 bids invited between 2010 and 2013)
Daelim Industrial
E&C Unit
Plant
01 | Introduction
5
8.2 6.0
7.7
2012
7.9
2013
8.2
2014
New Orders (USD billion)
7.06.5 5.9
Sales (USD billion)
2012 2013 2014
388
177
60
Operating Profit (USD billion)
2012 2013 2014
(FY2014)
52%31%
17%
59%23%
18%
(FY2014) Building &
Housing
Civil
Plant Building &
Housing
Civil
Plant
FinancialHighlights
Daelim Industrial
E&C Unit
New Orders Sales
USD Billion USD Billion
02 | CCS R&D Outline
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� Characteristic of CO2 capture plant from flue gas
� Very low pressure� High CO2 concentration� Oxygen� SO2� Huge gas volume� High corrosive environment
Low Energy consuming New Capture Technology
02 | CCS R&D Outline
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Effective Design of Process and Scale-up
(DAELIM)Developing Solvent
(KEPCO Research & Institute)
Cost / Quality Competitiveness
Advanced Solvent
Power Plant
BusinessPlant Engineering
Plant Construction,
Integration with Power plant
(KOREA Power, KEPCO E&C,
POSCO E&C)
World Best CO2 Capturing
� R&D Needs
World Best CO2 Capturing
02 | CCS R&D Outline
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Developing Solvent(KEPCO Research & Institute)
Cost / Quality Competitiveness
Advanced Solvent
Power Plant
Business Plant Engineering
Plant Construction,
Integration with Power plant
(KOREA Power, KEPCO E&C,
POSCO E&C)
� R&D Needs (Advanced Solvent / Power Plant Business)
02 | CCS R&D Outline
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� R&D Needs (Advanced Solvent / Power Plant Business)
Advanced Solvent Power Plant Business
KEPCO Research & Institute)KOREA PowerKEPCO E&CPOSCO E&C
• Many experiences in the development of advanced solvent for Post-combustion (Coal fired)
• Plant Construction
• Plant Operation & Maintenance
• Integration with Power plant
• Optimization of Energy utilization
Good advanced proprietary solvent (KoSol series)Good construction & integration
World Best CO2 Capturing
02 | CCS R&D Outline
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Effective Design of Process and Scale-up
(DAELIM)
Cost / Quality CompetitivenessAdvanced Solvent
Power Plant
Business
Plant Engineering
� R&D Needs (Plant Engineering)
02 | CCS R&D Outline
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� R&D Needs (Plant Engineering)
Plant Engineering
Daelim Industrial Co., Ltd.
Engineering Simulation
• Many experiences in Amine Treating Process (Refinery and Gas plants)
• Basic Design / FEED Design / Detail Design
• Many Simulation programs• Experiences in simulation of CO2 capture
process using specialized program in Amines
Good engineering, Good commercial programs
How does it work on new advanced solvent ??
02 | CCS R&D Outline
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Cost / Quality CompetitivenessAdvanced
Solvent
Power Plant
BusinessPlant Engineering
World Best CO2 Capturing� R&D Needs (Plant Engineering)
DEDICATED NEW SIMULATION PROGRAM
02 | CCS R&D Outline
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Part 1
Low energy consumingCO2 capturing solvent
developing
KEPCO Research & Institute
Part 2
CO2 capture process basic design
DAELIM
Part 3
CO2 capture plant construction and
operation
KOMIPO / POSCO
Part 4
CO2 capture plant integration with
power plant
KEPCO E&C
Overall R&D Project
Development of Commercial Package of 10MW Post-combustion Advanced Amine CO2
Capture Technology
KEPCO Research & Institute
Monitor / Adjustment / Guide
� R&D Organization and R&R
02 | CCS R&D Outline
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Demonstration Plant
Coal power plant 150 MW
Pilot Plant
Coal power plant 10 MW
Test Bed
Coal power plant 0.1 MW
Boryeong Location ?
Improvement suggestion
Scale-up study Demonstration
Boryeong
� Scale-up
03 | Pro-II UAS Programming
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PRO-II AA BB CCMerit
- Active technical support
- Similar experience
Many users- Specializedprogram for amine treating unit
- Many experiencein amine treating
Specialized program for amine treating unit
De-MeritGeneralized on hydrocarbon processing
- Relatively highercost
- Generalized on hydrocarbon processing
Not allow to open the source code Not proven
Remarks Korea agent Korea agent Korea agent No Korea agent
� Why did Daelim choose Pro-II?
03 | Pro-II UAS Programming
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� Development of Process Simulation with KoSol1) Thermodynamics modeling and its incorporation into PRO II
* User Library for new amine components
* User-added thermo for reaction equilibrium calculation
- Kent Eisenberg Model (Ionic equilibrium reaction and Vapor-liquid equilibrium(Henry’s law))
* Enthalpy calculation
* Utility program for parameterization of equilibrium constants
2) Mass-transfer modeling and its incorporation into PRO II
* User-added mass-transfer for the absorption kinetics
* Utility program for parameterization of mass-transfer coefficient
3) Software configuration
DLL for user-added thermodynamics model
DLL for user-added mass-transfer model for RATEFRAC
03 | Pro-II UAS Programming
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� Work Flow for Process Simulation Development (KoSol)
Properties of KoSol
� Heat of vaporization input� NRTL parameter value
input� Henry’s coefficient� Etc.
Set Equilibrium Reaction/ Mass transfer
Equations
UAS Programmingfor Reaction
in PRO/II
� Reaction� Mass-transfer
Parameterizationw/ Experimental data
Validation Workfor UAS
Programing
CCS Process Simulation (test)
ActualOperating Data
Tuning Work forUAS Programming
� component properties� k-value� liquid enthalpy� RATEFRAC enhancement� Etc, if required CCS Process Simulation
(150 MW)
SimSci Scope
03 | Pro-II UAS Programming
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Daelim’s scope SimSci’s scope
• Providing the required Property Data for new solvent
• Measure the heat of reaction
• Validation the built-up UASs together with Invensys
• Build the CCS simulation model
• Gathering the actual operating data in the pilot plant
• Tuning work of UASs based on operating data
• Build the final CCS simulation model and Basic Design
Package
• UAS for Equilibrium reactions from experimental data
– User Added Subroutine program (UAS) is made to attach in the PRO/II
– UAS is communicated with the source code in PRO/II.
– Equilibrium reactions to be generated based on Kent Eisenberg equation and it to be developed together with Invensys.
• UAS for mass transfer from experimental data
– User Added Subroutine program (UAS) is made to attach in the PRO/II
– UAS is communicated with the source code in PRO/II.
– Mass transfer UAS to be built to predict absorption kinetics
• Training for UAS building
– Training for the procedure of building UAS
� Scope split between Daelim and SimSci
03 | Pro-II UAS Programming
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� Registration of New Databank (KoSol)1) Existing Components
* Using a SIMSCI databank or a PRO II Process databank
2) New Components
* Estimation by PROPRED system (registration of molecular structure)
3) Added experimental value (ex : boiling point, etc)
* Using “Experimental Data and Calculation Options”
4) Protection
* Component information (Name, Structure, etc)
* Property data (Temperature dependent parameter, Physical property data, etc)
03 | Pro-II UAS Programming
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Work title Objectives Activities Data required
Thermo/mass-
transfer core program
Create prototype program to predict VLE based on reactions.
Create a prototype on VBAComponents and
expected reactionsObjective acid components
Create prototype program to predict mass-transfer coefficient based on
Hatta TheoryCreate a prototype on VBA
Parameterization
Determine parameter values to predict VLE based on reactions.
Determine reaction equilibrium Constant
Loading curve data at plural temperature levels in
expected operation range of Temperature
Determine activity Coefficient
Data on evaporation of Amines
Determine parameters for enthalpy
Determine superficial heat of vaporization
Heat of reaction
Heat capacity of the mixture Heat capacity data
Determine parameter values to predict density, viscosity
-Density and viscosity of the
solution
Determine parameter values for mass-transfer coefficient based on
Hatta Theory
Determine paramters on Hatta number (k/D)^0.5
Data on enhancement of absorption rate by adding
additives.
� Detail activities per step (1/2)
03 | Pro-II UAS Programming
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Work title Objectives Activities Data required
Incorporation to PRO/II
User added subroutine for VLE (directly connected to
PRO/II) and mass-transfer (connected to RATEFRAC)
Check the VLE and mass-transfer predicted by UAS are the same with those by
stand alone programs
-
Test by PRO/II
prototype
Create a prototype simulation file on PRO/II using the features developed in this work and check if they work
well.
-The expected process flow diagram and feed flowrate.
� Detail activities per step (2/2)
03 | Pro-II UAS Programming
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10MW Pilot plant
� Commercialized simulation
� Basic design by DAELIM
Dedicated Pro-II UAS programming and Tuning
150MW CO2 capture plant
� Application of dedicated Pro-II UAS
� Basic design by DAELIM
� Transition history of Process simulation for KoSol
03 | Pro-II UAS Programming
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UnitBefore the
tuning[ A ]
After the tuning[ B ]
Operation[ C ]
Gap %[(B-C)/Cx100]
Duty
of condenserMMkcal/hr 3.17 1.36 1.47 7.4
Duty
of reboilerMMkcal/hr 6.64 5.37 5.63 4.6
Density
for lean/rich
amine solution
kg/m3 1000/906 1130/1039 1117/1038 0.6
� Tuning results of PRO-II UAS
Further sufficient tuning work to be required on the basis of much more operating data.
03 | Pro-II UAS Programming
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UnitCommercial Program
[ A ]
PRO II UAS
[ B ]
Gap %
[(A-B)/Ax100]
Duty
of condenserMMkcal/hr 28 15.1 46
Flowrate of Reflux ton/hr 44 26 41
Duty
of reboilerMMkcal/hr 76.6 82.8 8.1
Regeneration
EnergyGJ/tonCO2 2.56 2.76 7.8
Density
for lean/rich amine
Solution
kg/m3 1109/998 1100/933 0.8/7
� Comparison with Commercial program
There is an obvious practical optimization of design through PRO-II UAS Program.
04 | Future Plan
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– Addition of function to execute simulation of theoretical tray column:
To reach quickly to the results during many case studies
– Simultaneous application of various packing types in RATEFRAC
Calculation
– Continuously tuning of our program based on various operating data
(The more gathered operating data, the more reliable)
� Further Development for PRO-II UAS Program
Some part of above mentioned items will be executed through another project with
SimSci.
04 | Future Plan
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� Strategy for Commercialization
– Design optimization through the developed PRO-II UAS Program
– Meet various potential Client’s needs through case studies through the program
– Continuously operating of 10 MW Boryeong CCS facility to verify high reliability of
our CO2 capture technology
– First, application of our CO2 capture technology in Korea CCS Demonstration
project
– Next, entry into Global CCS technology market
– Also, entry into Global CCS EPC market as Global EPC contractor
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Thank you !
I want to express my thanks to Mr. Hirohama, Ms Miyaoi and
Mr. JC Lee, who are working for Schneider-Electric.