Enhanced Cryogenic Air SeparationEnhanced Cryogenic Air Separation A proven Process applied to OxyfuelFuture Prospects
Dr -Ing Gerhard Beysel
Future Prospects
Dr. Ing. Gerhard Beysel1st Oxyfuel Combustion ConferenceCottbus, Sept 8th, 2009
Agenda
1 Introduction
2 Air Separation Technologies
3 Potentials for Power Savings and Cost Reduction
4 Potentials for Large Capacities and Oxygen Demand for New4 Potentials for Large Capacities and Oxygen Demand for New
Applications
5 Innovative Improvements at Cryogenic Air Separation
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The Linde Group The Divisions
Linde EngineeringLinde Gas
(Headquarter Munich, Germany)
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( y)
50 000 employees Sales 17 billion US$2006
Linde Engineering DivisionProduct Lines & Key Plant TypesTypes
Olefin Plants
— Products:
Natural Gas Plants
Products: Products:— LNG— NGL— LPG— Helium
Products:— Ethylene— Propylene— Butadiene— Aromatics
— NRUAromatics
— Polymers
Air Separation PlantsHydrogen and Synthesis Gas Plants
— Products:— Oxygen
— Products:— H2/CO/Syngas Oxygen
— Nitrogen— Rare gases
H2/CO/Syngas— Ammonia— Gas removal— Gas purification
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Carbon Capture Technologies (CCS) - From the ASU Perspective -
Technology Process Linde Portfolio
1. Pre-Combustion(IGCC)
GasifierASU
Gas cleaningCO Shift
CO2 Liquefaction
&(IGCC) er g(Rectisol) &
Compression
Feedstock
Feedstock CO2
2. Oxyfuel(Oxycoal)
DeSOxBoilerASU DeNOxCO2
Liquefaction &
Compression
CO2
3. Post-Combustion(PCC)
DeSOxBoiler DeNOx
CO2 capture &
Compression
Feedstock
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(PCC) p
CO2
Air Separation PlantsSimplified Air Separation Process
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Air compression, -precooling and -purification
heat exchange, refrigeration,rectification and internal compression
productdistribution
Alternative Air Separation Technologies
Cryogenic Air Separation (ASU) the principles invented one century ago (Dr. Carl von Linde) developed for large volumes of oxygen and nitrogen with high purities developed for large volumes of oxygen and nitrogen with high purities commercialized for industrial application in a wide range the source for Industrial Gas Companies supply schemes Continuous development and improvement , >25% power saving possible
Polymeric Membranes and Moleculare Sieves (PSA, VSA) advantageous for small volumes - at lower purities produced at ambient temperatures and as needed on-site
Oxygen Production by Chemical Air Separation (MOLTOX) Developed and pilot tested by Air Products with DOE funding in early 1990s >40% power saving predicted, compared with cryogenic processes Status and future of the process unknown (material- and corrossion problems)
High Temperature Ceramic Membranes (ITM) Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
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150 tpd under development; >30% power saving predicted
Alternative Air Separation Technologies - Potentials to Reduce Power Consumption and CostCostCryogenic Air Separation (ASU)
the principles invented one century ago (Dr. Carl von Linde) developed for large volumes of oxygen and nitrogen with high purities developed for large volumes of oxygen and nitrogen with high purities commercialized for industrial application in a wide range the source for Industrial Gas Companies supply schemes Continuous development and improvement , >25% power saving possible
High ++
Polymeric Membranes and Moleculare Sieves (PSA, VSA) advantageous for small volumes - at lower purities produced at ambient temperatures and as needed on-site
medium+
Oxygen Production by Chemical Air Separation (MOLTOX) Developed and pilot tested by Air Products with DOE funding in early 1990s >40% power saving predicted, compared with cryogenic processes
?
Status and future of the process unknown (material- and corrossion problems)
High Temperature Ceramic Membranes (ITM) Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
High ++
Bey/L/092009/Cottbus.pptLinde AG Engineering Division 8
150 tpd under development; >30% power saving predicted
High ++
Alternative Air Separation Technologies - Potentials to Supply Large Product Flows
Cryogenic Air Separation (ASU) the principles invented one century ago (Dr. Carl von Linde) developed for large volumes of oxygen and nitrogen with high purities developed for large volumes of oxygen and nitrogen with high purities commercialized for industrial application in a wide range the source for Industrial Gas Companies supply schemes Continuous development and improvement , >25% power saving possible
High ++
Polymeric Membranes and Moleculare Sieves (PSA, VSA) advantageous for small volumes - at lower purities produced at ambient temperatures and as needed on-site
low
Oxygen Production by Chemical Air Separation (MOLTOX) Developed and pilot tested by Air Products with DOE funding in early 1990s >40% power saving predicted, compared with cryogenic processes
?
Status and future of the process unknown (material- and corrossion problems)
High Temperature Ceramic Membranes (ITM) Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
?
Bey/L/092009/Cottbus.pptLinde AG Engineering Division 9
150 tpd under development; >30% power saving predicted
?
Typical Oxygen Demand for New Applications
New Applications Capacity [MW] Oxygen [tons/day ]
IGCC (demo) 250 - 300 MW - 2.000 1)
IGCC, Oxyfuel (demo) 300 - 600 MW 2.000 - 5.000 1)
CTL, Polygeneration (project) 1500 MW, yg (p j )25.000 1)
GTL (demo) 12.000 bpd 2.500 2)
GTL (commercial 35.000 bpd 7.000 2)
scale)GTL (commercial scale)
140.000 bpd 30.000 2)
Cryogenic ASUs: Single train sizes with a capacity of 5.000 tons/d are available
1) Low puity oxygen <95%
capacities < 7.000 ton/d under development
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Low puity oxygen 95%2) High purity oxygen >99,5%
Cryogenic Air Separation – Capacity Increase
1902 : 2006 :
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1902 :5 kg/h(0,1 ton/day)
2006 :1,250 Mio kg/h(30.000 ton/day)
Air Separation Plants – Shell „Pearl“ GTL Project Qatar30 000 tons/day Oxygen30.000 tons/day Oxygen
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Air Separation Plants – Shell „Pearl“ GTL Project Qatar30 000 tons/day Oxygen30.000 tons/day Oxygen
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Large Tonnage ASU Coldbox Shipment for „Pearl“ GTL project
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Tonnage Air Separation PlantsMega Plants for new Applications
Cryogenic Air Separation Process OptimizationCryogenic Air Separation Process Optimization
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Air Separation Process Conventional Design (mit Einblaseturbine)
PG
AN
GO
X
-6 b
ar
ar
onne
5.5-
1.05
ba
Wär
met
ausc
her
Boo
ster
Turb
ine
ator
Nie
derd
ruck
kolo
Kon
dens
a
G
ochd
ruck
kolo
nne
UK
G
-5.8
bar
Oxygen: 95%, gaseous, at ambient pressure
Features:
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Ho
5.3
PNitrogen: up to 30% of airflow available
Air Separation Process Advanced Alternative Design(mit warmer PGAN-Turbine)(mit warmer PGAN-Turbine)
GO
X
GPOWER
Power Wärme/Abwärme
5.2-5.7 bar
PG
AN
Vorkühlung Adsorber
R t
AIR5.
5-6
bar
1.2-1.3 bar
1.05
bar
Wär
met
ausc
her
oste
r
rbin
e
1 r
Nie
derd
ruck
kolo
nneRestgas
Bo Tu
1 Kon
dens
ato
G
Oxygen: 95%, gaseous, at ambient pressure
Hoc
hdru
ckko
lonn
e
UK
G
5.3-
5.8
bar
Features:
reduced energy consumption/power recovery by expanding
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5
PGAN
heat integration
Air Separation Process Advanced Alternative Design (“Dual Reboiler”-Design)Design)
GO
X
5 ba
r
bar
derd
ruck
kolo
nne
4.5
1.05
b
Wär
met
ausc
her
Boo
ster
Turb
ine
dens
ator
2
Nie
d
UKG
Kon
d
e
U
onde
nsat
or 1
Oxygen: 95% gaseous at ambient pressure
Hoc
hdru
ckko
lonn
eKo
4.3
bar
Oxygen: 95%, gaseous, at ambient pressure
Features:
reduced process air pressure
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reduced process air pressure
reduced power consumtion
Air Separation Process Advanced Alternative Design (3-column Design)
GO
X
.5 b
ar
bar
4.
1.05
Wär
met
ausc
her
Boos
ter
Turb
ine
Kon
dens
ator
2er
druc
kkol
onne
2
UKG
Nie
de
ensat
or 1
uckk
olon
ne 1
Oxygen: 95% gaseous at ambient pressure
Hoc
hdru
ckko
lonn
e
Kond
en
4.3
bar
Nie
derd
ru Oxygen: 95%, gaseous, at ambient pressure
Features:
reduced process air pressure
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reduced process air pressure
reduced power consumtion
Air Separation UnitsCryogenic Oxygen / Specific Energy ConsumptionConsumption
Conventional Process Schemes / - Applications
kWh/Nm³ 1) kWh/Nm³ 2) kWh/t (metric ton) 3)kWh/t (short ton)
(= 907,2 kg) 3)
Conversion Figures:
1 O,95 699 635
0,35 kWh/Nm³ O,33 kWh/Nm³ 245 kWh/t 222 kWh/t
Conventional ASU, Oxygen Purity >99.5%
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1) used by ASU vendors (Linde et al) and commonly used for process calculation 2) used by Gas Companies 3) 1 Nm³ = 1,429 kg
Air Separation UnitsCryogenic Oxygen / Specific Energy ConsumptionConsumption
Advanced Process Schemes for New Applications, e.g. IGCC, Oxyfuel, IGSC
kWh/Nm³ 1) kWh/Nm³ 2) kWh/t (metric ton) 3)kWh/t (short ton)
(= 907,2 kg) 3)
Advanced, energy optimized ASU, 95 % Purity Oxygen
0,25 0,237 175 159
Power consumption reduced by > 25% !!
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Above Figures are related to 100% Oxygen (contained Oxygen), normal ambient conditions for design: 20°C, 15°C CW, 60% rel. humidity, at sea level
Air Separation PlantsMega Plants for new Applications
Power Plant Specific Requirements and their consequencesp q q
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Air Separation Units for Power Plants Specific Requirements
Specific Power Plant Requirements:
lowest possible power consumption
CAPEX and OPEX optimization
operation range from 60 to 105%
load change > 2% per minute
oxygen purity 95%
low product pressure
Differences between Power Plant Standards and conventional Industrial Gases
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Standards
Air Separation Units Specific Requirements for Power Plants
If project specific requirements:If project specific requirements:
Design margin of 5%,
turndown to 63%,
design for maximum ambient conditions,
liquid production liquid production
are not to be considered for design,
potential for further power saving of 8%.
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Air Separation Units for Power PlantsAir Compression Efficiency
Impact of Turndown Requirement on Main Air Compressor EfficiencyImpact of Turndown Requirement on Main Air Compressor Efficiency(For a typical ASU)
Turndown Power at motor terminal Additional powerComparison
75 to 80% 18 500 kW 100 %
63% 19 100 kW + 600 kW 103 %
56% 19 500 kW + 1000 kW 105 %
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Air Separation Units for Power PlantsAir Compression Efficiency
Impact of Different Ambient Air TemperaturesImpact of Different Ambient Air Temperatures
Ambient Air Temperature -17°C 9°C 30°C 33°C
Effective Air Volume Flow 91% 100% 107% 109%
plus 5% design margin
plus turndown requirementplus turndown requirement
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Load change scenario: Ramping of process parameters Target > 2%/min – fluctuation of oxygen purity? Target > 2%/min – fluctuation of oxygen purity?
Load change scenario - conventional process scheme considered ramping > 4 %/min
350000
400000
0 98
0,99
1
250000
300000
0,96
0,97
0,98 Oxygen Purity
150000
200000
Nm
³/h]
0,94
0,95
O2
[%]
Mair
MGOX
O2_%
50000
100000
0,91
0,92
0,93
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00 2000 4000 6000 8000 10000 12000 14000
Time [sec]
0,9
Air Separation Units for Power PlantsSummary, Low Power Consumption
Steps to low power consumption of ASU:
apply highly efficient air separation process
select appropriate compressor model
identify possibilities for power/heat integration
pick advantageous driver option
check operations requirements carefully (turn down, design margin, etc.)
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Advanced Cryogenic Air Separation - innovative improvements for new applications
Advanced Structured Packings instead of sieve tray columns available
reducing pressure drop , increasing turndown capacity
Advanced process control systems, ALC (AutomaticLoadChange)p y ( g )available
Dynamic Simulation
Compressors with higher efficiency, larger turndown range development
High efficient Heat Exchangers available
Advanced process schemes 1) available
1) Large Scale Low Purity Oxygen Requirement (e.g. 95%) - is a novalty in Cryogenic ASU applica
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g y yg q ( g ) y y g pp
leads to a step change energy reduction compared to traditional applications !
Linde Engagement in CCS – Oxyfuel
Linde has built an air separation plant and a CO2 purification and liquefaction plant for Vattenfall’s first oxyfuel pilot plant for coal-based power generation
Linde Portfolio
with CO2 capture.
Oxyfuel Combustion
Portfolio
CO2 to Storage
H2O Condensation CO2 LiquefactionAir Separation Unit
Steam
N2 Free Flue Gas
OxygenCombustion
&Power Generation
&
CO2 Recycle
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Feedstock&
Steam Generation&
Heat Recovery
Groundbraking Ceremony May 2006
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Oxyfuel Pilot Plant Schwarze Pumpe –3-D Model
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Oxyfuel Pilot Plant Schwarze PumpeOfficial Inauguration and start-up: Sept. 9th 2008
Boiler
Dust filter ASU
DSU
FGC
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CO2 plant Control room
Vattenfall Oxyfuel Powerplant Schwarze PumpeLinde Scope: ASU, CO2 Plant; TechnologiepartnershipTechnologiepartnership
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Vattenfall Oxyfuel Powerplant Schwarze PumpeASU with LCO2 Tank
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Vattenfall Oxyfuel Powerplant Schwarze PumpeCO2 Plant with LCO2 Tanks
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Linde Engagement
„Coal or petcoke gasification, Oxygen for CO2-free power
generation, Hydrogen for refinery applications, LNG, and Gas To
Liquids, are all energy related development trends where Linde is
engaged and offers appropriate technologies and know-how “engaged and offers appropriate technologies and know-how.
Linde - the Pioneers of Air Separation – we are able to respond to
the challenge of producing cleaner fuel & energy for the growing
ld id d dworldwide demand.
(Dr. Aldo Belloni , CEO-Linde)
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Thank youThank youfor your attention.
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