Progress on CO2 Capture Pilot Plant at RIST - ieaghg.org and Steel 2 Secured... · 6 Results -waste heat recovery to generate “low pressure steam” 발전소배가스열교환시스템

November 5, 2013

RIST (Research Institute of Industrial Science & Technology)

Progress on CO2 Capture Pilot Plant at RIST

IEAGHG/IETS Iron & Steel Industry CCUS & Process Integration WorkshopDate: 5th to 7th November 2013Tokyo Tech Front, Tokyo Institute of Technology, Japan

1

Contents

History of Aqueous Ammonia-based CO2 Capture Technology

Results of AA-based CO2 Capture Pilot Test

Results of Simulation studies

2013 Pilot Plant Operation Results

2013-2014 Plan

Concept for RIST CO2 Capture Process

2

“Absorption” is a clever choice for the CO2 capture considering the feed gas condition.

Why “Absorption” for CO2 capture?

CO2 concentration (%)

Pre

ssur

e(a

tm)

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

Chemical Absorption-Amine, Ammonia

Chemical Absorption- K2CO3

Physical Absorption-Selexol, Rectisol

Membrane/Adsorption

-PSA

Cryogenic

BFG

Component CO2 CO N2 impurities

BFG (%vol) 20-23 22-25 53-58 Dust, H2S, HCN

Feed gas: BFG, has low heating value (~800kcal/Nm3)- If remove CO2, the heating value of the BFG will increase by approximately 30%

3

Why ammonia-based CO2 capture for iron industry?

▪ Low Corrosiveness : Low construction cost, Easier maintenance, Duration of equipment à Low Capex

▪ Low Chemical Cost : Low operating cost

▪ Low Regeneration Temperature : use waste heats in the iron and steel process

AbsorbentProperty Amines NH3

Absorption Capacity[mol-CO2/mol-absorbent] 0.5 (MEA) 1.0

Regeneration Temp. 120~140 ℃ (MEA) 80-85 oCPrice 1 (MEA) 0.17

Absorbent volatility Low High

Corrosiveness high lowThermal/Oxidative Degradation

(O2, SOx)Severe

(Forms heat stable salts) No degradation

Technical Issues

- Require anticorrosive agent- Higher regeneration temperature- Higher regeneration energy- Health and environmental impacts of amines and their degradation products

- High volatility à Ammonia loss- Slower absorption kinetics

Amines vs. Ammonia

Low Opex

4

Steam from waste heat (120 ℃, 1barg)

RIST NH3 based CO2 capture concept

Process schematics

No additional heat input required from outside !!

5

R&D history

Research milestones• ’06.-: Project initiated • ‘06-’08.: Lab-scale research • June ’09.-June ’10.: 1st stage P/P (50 Nm3/hr, 0.5tCO2/d) operation, CO2 recovery:90%, CO2:>95%• Nov. ’10. - : 2nd stage P/P (1,000 Nm3/hr, 10tCO2/d) operation• May ’12. - : CO2 purification/liquefaction facility operation

§ 1st stage P/P: 50 Nm3/hPOSCO - Pohag Works

CO2 capture

CO2 purification/ liquefaction

§ CO2 capture/purification/liquefaction§ 2nd stage P/P: 1000 Nm3/h

- Liquid CO2 with industrial grade could be produced of at a rate of 3 ton/day since May 2012.- Purity of product L-CO2 ≥ 99.8% (Liquid)

6

Results - waste heat recovery to generate “low pressure steam”

발전소배가스열교환시스템

Low and mid-temp. waste heat recovery system (Closed Loop)

To Reboilers

Waste HeatRecovery

CO2 Capture

▪ Integration of CO2 capture process and waste heat recovery system has been completed.▪ Production of G steam (1 barg at 120℃) using waste heat from boiler stacks▪ Successfully supplied G steam to the CO2 capture pilot facility (10t-CO2/day):

Integration of CO2 capture process and waste heat recovery system

7

Results – technical performances

▪ CO2 removal efficiency ~ 90%

▪ CO2 purity of product stream > 95% (~98%)

▪ Increase of CO content in BFG (~23%à33%) : Heating value increase in BFG

■ Tests w/ pilot facilities• Runs since May 2011 with the current pilot facility

(~ 100 hrs/run)• BFG provided by a slip stream• Ammonia concentration < 10 wt%

▪ Performance - w/ steam generated from waste heat recovery

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Experimental – test conditions

Major operation variables

Feed Gas: Load of feed gasT/P

Absorbent: Ammonia concentrationFlow rate of circulating absorbent

solution

Wash Water: WW temperatureFlow rates of WW

Others: Types of internalEfficiency of heat exchangersRatio of pump-aroundAddition pump-around

To reduce energy consumption

Time consuming and Too expensive !!

9

A simulation study of the aqueous ammonia CO2 capture process

Feed gas BFG (Blast Furnace Gas)BFG Rate: 1,000Nm3/hrBFG Inlet Temperature: 37℃BFG Inlet Pressure: 650 mmH2OgFeed Gas Composition

Systemconfiguration

Absorber, Regenerator, Concentrator

Ammonia concentration

9 wt%

CO2 recovery 90% (Mole basis)

CO2 con. >95% (Dry & Mole basis)

Component BFG Inlet Conc. (mole fraction)

H2O 0.08

CO2 0.21

N2 0.50

CO 0.21

Process design basis

Absorber Regenerator

Concentrator

Aspen Plus w/ Rate-based model

1010/22

<Absorber> <Regenerator> <Concentrator>

A rate-based simulation model of the ammonia-based CO2 capture process was developed using Aspen Plus 7.3.

The model was adjusted with the experimental results from the pilot plant and validated.

Aspen Plus w/ rate-based model

Parameter study to reduce the thermal energy requirement!

A simulation study of the aqueous ammonia CO2 capture process

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- Parameters to be considered: Circulating absorbent solution, heat integration, Absorption pressure, Pump around

Parameter study

Circulation

Heat Integration

Pump around

Pressure

Parameter

A simulation study of the aqueous ammonia CO2 capture process

Lean Sol.

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CO2 capture process parameter study

Regeneration energy reduction estimated by process simulation

Process variables Application plan

1 Absorbent flow rate -

2 Heat exchanger Modified and Tested (2013)

3 Additional pump-around - Absorber Modification scheduled (2014)

4 Lean solution cooling hold

- The regeneration energy was 3.1 GJ/t-CO2 (2012), so it could be reduced considerably.

1313

■ Process modification

§New heat exchanger - New HX: Rich solution-Lean solution)

New HX

[Process modification]

55à65oC

Year 2013 activities

54oC

60oC

New heat exchanger

New blower for higher absorber pressure

1414

Year 2013-14 action plan to reduce regeneration energy

■ Additional pump around - Currently, one PA installed at Absorber - With additional PA, higher CO2 capture capacity- Action plan

~ March ’14.: Construction~ May ‘14.: Performance test

- Continuous long-term operation for 500~1,000 hrs- Scheduled: Oct. ’13. ~ Nov. ‘13 - Evaluate process economics

■ Long-term operation

- Ammonia concentration: 9 wt% (current value to minimize NH3 loss)~ up to 12%

- With higher NH3 concentration, the solvent flowrate could be reduced- Additional regen. energy reduction expected- Scheduled: Oct. ’13. ~

■ Higher NH3 concentration in absorbent solution

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Scale-UpScale-Up

CommercialCommercialP/PP/P

■ Basic engineering design for commercial scale

§ Major deliverable

- 100X current pilot plant (50MW scale, CO2 Capture 1,000ton/day)

- Process Design Basis & Data

- Process Simulation

- Heat & Material Balance

- Process Flow Diagram (Including Major Control Scheme)

- Utilities & Chemical Consumption

- Equipment List, Equipment Data Sheet

- Piping & Instrument Diagram

- Equipment Location Plan (Plot Plan)

- Material Selection Diagram

- Instrument List with Process Data

- Project Cost Estimation

~ ‘13.11 ’13.11~’14.03

Basic engineering

Basic engineering package

■ Schedule

Contract CAPEX, Plot Plan, Operation Cost

Year 2013-14 action plan

Thank You!