post-combustion capture pilot plant operation in australia

Post-Combustion Capture Pilot Plant Operation in Australia and China

Paul H. M. Feron (OCE-Science Leader & PCC Stream L eader)12th Meeting of the International Post-Combustion CO 2 Capture Network, Regina, 29-30 September 2009

IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009

Overview

� Introduction�CSIRO’s PCC programme�The pilot plants

• Loy Yang Power

• China Huaneng

�Acknowledgements


Introduction


Coal is important for Australia

�Australia is the world’s largest coal exporter & coal is Australia’s greatest export earner (24.5B$ in 2005-06)

�Most of Australia’s electricity is produced from pulverised coal fired boilers (60% black coal, 20% brown coal)

• Generation capacity ~ 28 GW

• Electricity production ~ 170 TWh/a• Average generation efficiency

• Black coal: 35.6% - 0.9 tonne CO2/MWh

• Brown coal: 25.7% - 1.3 tonne CO2/MWh

• CO2-emissions ~ 170 Mtonne CO2/a from ~ 60 flue gas streams


The Top Emitting Countries – Stationary Energy

0

500

1000

1500

2000

2500

Tot

al (

MtC

O2)

Chi

na US

Indi

a

Rus

sia

Japa

n

Ger

man

y

Au

stra

lia

S. A

fric

a

UK

S. K

orea

Can

ada

S. A

rabi

a

Indo

nesi

a

Fra

nce

0

2

4

6

8

10

Per

Cap

ita (

tons

/per

son)

CO2 from Electricity and Heat, total and per Capita, 20 05

Source: IEA, 2005

Total

Per Capita


CSIRO’s PCC programme


PF Power Plant with Post Combustion Capture in Australia


Pilot plant programme (Learning by doing)� Hands-on experience for future operators� Identification of operational issues and requirements� Testing of existing and new technologies under real

conditions

Lab research programme (Learning by searching)� Support to pilot plant operation and interpretation of

results� Develop novel solvents and solvent systems which

result in lower costs for capture� Addressing Australian specifics (flue gases, water)

Integrated PCC R&D Programme


PCC Programme Overview

PCC

Pilot plants Research & Development

Delta Electricity

Loy Yang Power

China Huaneng

Tarong Energy

Novel solventsCET Ionic liquids

CET

Novel processesCET

Economics & IntegrationCET

Solvent synthesisCMHT

AdsorbentsE&M

Environmental impactsCET

EnzymesENT


The pilot plants


Achievements: 3 pilot plants established in 2008

Latrobe Valley Post Combustion Capture Project

- APP support - Munmorah Power Station- Black coal- Ammonia based- No FGD/DeNox

- APP support- Gaobeidian Power Station- Black coal- Amine based- FGD/DeNox installed

- ETIS support- Loy Yang Power Station- Lignite- Amine based- No FGD/DeNox


PCC pilot plant at Loy Yang Power


Latrobe Valley Post-combustion Capture Project(ETIS – programme)


Latrobe Valley Post-Combustion Capture Project

• Identification of cost-effective options for reduction of CO2-emissions in Victorian brown coal fired power stations

• Determine effects of CO2-concentration, moisture content, SOx, NOx and fly-ash on sorbent systems and novel separation technologies

• Technical and economical assessment based on results from pilots and laboratory research

• Develop experience in the operation of PCC plants


Loy Yang Pilot PlantSimplified Process Flow Diagram


Pilot plant scale : 50 kg/hDesign CO 2 capture : 90%Solvent base : MEA 30%Commissioned : July 2008

Stripper

Absorber column 2

Caustic WashColumn

Solvent Feed Tank

Absorber column 1


Plant Specification

Absorbers:- 200DN stainless steel pipe (211 mm ID)- The column height: 9.4 m- Packing height per column: 2.7 m (2 x 1.35 m)

Stripper:- 150DN stainless steel pipe (161 mm ID)- Stripper height : 6.9 m- Packing height: 3.9 m.

Pall ring packing, (i) packing size in every sectio n is 160 mm, (ii) specific area of packing is 338 m 2/m3

and (iii) packing factor (1/m) is 306.


PCC Loy Yang R&D Path(Artanto et al., 2009)

2008 2009 2010

01

02

03Performance of pilot plant at different conditions using MEA based solvent

Installation andcommissioning

04

06

05

07Performance of pilot plant at different conditions using blended & novel solvent

2011

Applicability study for integration between PCC and (New/exisiting) power station

research & development


Effect of L/G changes on CO2 recovery – 30% MEA(Artanto et.al., 2009)

50

60

70

80

90

100

1.5 2.0 2.5 3.0 3.5 4.0 4.5

L/G (L/Nm³)

CO

2 re

cove

ry (

%)


GASMET CEMS Properties(CEMS= Continuous Emission Monitoring System)

• For analyzing hot, wet and corrosive emission or process gases

• Based on On-Line FTIR technology. • No sample preparation, drying or dilution

→ Always representative sample gas• Even difficult gases can be analyzed: HCl,

HF, HCN, NH3, …• Fully automated continuous measuring

system, complete user control in manual mode

• Fullfills TÜV (17 BlmSchV), MCERTS, and ISO EN 14181


Emission measurements: Preliminary results

�Solvent: 25-30% MEA�Absorber wash not operated during experiments�Plant is operated discontinuously�Campaign length: 3 months with same batch�Values are indicative given the error range�Measured emissions are the sum of liquid carry-over

and vapours


Average gas composition typical experiment

197

< 1 ppm

< 5 ppm

8.1

8.0

2.2

41.0

Exit ABS column 1

207

< 1 ppm

< 5 ppm

6.5

5.7

12.2

32.8

To ABS column 2

< 1 ppm< 1 ppmNO2 [ppm]

< 10 ppm183NO [ppm]

< 5 ppm164 SO2 [ppm]

< 0.01 5.1O2 [%]

2.221.2H2O [%]

97.810.5 CO2 [%]

25.5150 – 170 Temperature [oC]

CO2 productInlet


MEA Vapour pressure over 30% MEA solution(Aspen Plus data)

1.00E+00

1.00E+01

1.00E+02

1.00E+03

0 0.1 0.2 0.3 0.4 0.5 0.6

Loading [mol CO 2/mol MEA]

ME

A c

once

ntra

tion

[ppm

v]

40 oC

60 oC

80 oC

Loading Range

STEL= 6ppm


MEA exit concentration during campaign(Without water wash)

-

50

100

150

200

21-Feb-09 3-Mar-09 13-Mar-09 23-Mar-09 2-Apr-09 12-Apr-09 2 2-Apr-09 2-May-09 12-May-09 22-May-09 1-Jun-09

Date

ME

A c

once

ntra

tion

(ppm

v)


NH3 exit concentration during campaign(Without water wash)

-

10

20

30

40

50

60

70

80

90

100

21-Feb-09 3-Mar-09 13-Mar-09 23-Mar-09 2-Apr-09 12-Apr-0 9 22-Apr-09 2-May-09 12-May-09 22-May-09 1-Jun-09

Date

NH

3 co

ncen

tratio

n (p

pmv)


MEA exit concentration correlated with absorber temperature (Without water wash)

0

50

100

150

200

250

40 45 50 55 60

Temperature average in ABS col-1 ( oC)

ME

A c

once

ntra

tion

(ppm

v)


MEA exit concentration correlated with lean loading(Without water wash)

0

50

100

150

200

250

0.15 0.2 0.25 0.3

Lean loading (mol CO 2/mol MEA)

ME

A c

once

ntra

tion

(ppm

v)Solvent flow = 7 l/min Solvent flow = 5.5 l/min Solvent flow = 4 l/min


PCC pilot plant activities in China


Why PCC in China?

�China is the world’s largest producer and consumer of coal

�Energy demand growing rapidly – 800 GW of installed capacity – 70% based on coal

�China estimated to be third largest cumulative emitter by 2030

�Old inefficient power stations are being replaced at the rate of 15 GW/a

PCC is essential to achieve emission reductions from the relative young stock of coal fired power plants

Data: Xu, Shisen and Cai Ming, 2009


CSIRO PCC China programme: 4 Phases

Phase 1: Pilot plant at Huaneng Beijing Cogeneration Plant• Preparation• Construction and Installation• Preparation for commissioning and operation• Commissioning and operation

Phase 2: Pilot plant at second site• Discussions on transportable pilot plant

Phase 3: Technology scale up and international industry implementation

• Feasibility study for PCC under Chinese conditions

Phase 4: Outreach program• S&T seminar held in Australia on the use of aqueous ammonia for PCC• S&T seminar planned in China in 2010/2011


Roles in the cooperation of phase 1

�China Huaneng Group• Organising, Funding and management

�Huaneng Beijing Co-generation Plant • Construction and Operation

�Thermal Power Research Institute (Huaneng R&D Center)• Process Design, Equipment Design, DCS Design, Debugging and

experiment in the future

�Commonwealth Scientific and Industrial Research Organization

• Engineering drawing reviewing, Staff Training, etc


PCC in Huaneng Beijing Cogeneration Plant

Boiler SCR ESP FGD

TurbineCO2

capture

CO2refining

Steam

Power 3000 tpaFoodGradeCO2

Capture inlet gasCO2: 10%～15%O2: 5%～8%SO2: 100 mg/m3

Temp.: 40°C ～50°C


Design conditions (Cai Ming, 2009)

Design Capacity:• Flue Gas: 2372 Nm3/h (Wet)

• CO2 Captured: 0.5t/h

Steam conditions:• Pressure: 0.3 MPa

• Temperature: 144 oC

• Consumption:• Steam：≤ 2.0 t/ tCO2,• Amine: ≤1.5 Kg/tCO2

• Electricity: ≤ 92 kW

Solution composition• （1） Amine 18～22% (wt）• （2） Anti-corrosion solvent

• （3） Anti-oxidant solvent• （4） water

Captured CO2:• 271 Nm3/h (Wet)

• Composition in mol:

• CO2: 93.37%• N2: 0.33%

• H2O: 6.28%

• SO2: 0.01%• NOx:0.01%


Post-Combustion Capture Pilot PlantChina Huaneng Beijing Cogeneration plant/1

Under Construction



Capture plant overall Storage tanks and heat exchangers



Rotating Equipment Assembly CO2 Purification Unit


Providing training to Chinese engineers and scientists

Theory at Energy Centrein Newcastle

Practice at Loy Yang Power Station pilot plant


Pilot plant operation to date

�The first run was completed on 4th July 2008�9th July – 31st July 2008 commissioning and successive operation�Elimination of defects�Experimental operation to determine optimum operating conditions

�Flow rates: 1800-3200 Nm3/h (75%-135%)�CO2 in exhaust gas: 2% - 4%�Captured CO2 quality: 99.5%, 350-600 kg/h�1000 ton CO2 produced from flue gas since start-up�Refurbishment in 2009 leading to a better water balance


Acknowledgements

Members of the CSIRO PCC team who contributed to the presentation:

Loy Yang Pilot Plant:• Yuli Artanto, Aaron Cottrell, Erik Meuleman, James Jans en,

Mick Osborn, Rob Rowland, Moetaz Attalla, Pauline Pea rson, Delta Electricity Pilot Plant:• Hai Yu, Aaron Cottrell, James McGregor, Scott Morgan,

Andrew Allport, Anthony Callen, Narendra DaveHuaneng Beijing Cogeneration plant:• The colleagues at TPRI – Xu Shishen, Gao Shiwang, Lianb o

Liu, Tao Jiye, Cai Ming, Niu Hongwei, Huang BinProcess modelling• Thong Do, Ashleigh Cousins


Our supporters

TPRI : Thermal Power Research Institute


Contact UsPhone: 1300 363 400 or +61 3 9545 2176

Email: [email protected] Web: www.csiro.au

Thank you

CSIRO Energy TechnologyPaul H.M. FeronOCE Science LeaderPost-combustion CO2 CapturePhone: +61 (0)2 4960 6022Email: [email protected]: www.csiro.au

post-combustion capture pilot plant operation in australia

Documents