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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Introduction
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
CSIRO’s PCC programme
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
PF Power Plant with Post Combustion Capture in Australia
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
The pilot plants
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
PCC pilot plant at Loy Yang Power
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Latrobe Valley Post-combustion Capture Project(ETIS – programme)
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Loy Yang Pilot PlantSimplified Process Flow Diagram
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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.
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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 (
%)
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
MEA exit concentration during campaign(Without water wash)
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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)
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
NH3 exit concentration during campaign(Without water wash)
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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)
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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)
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
PCC pilot plant activities in China
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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%
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Post-Combustion Capture Pilot PlantChina Huaneng Beijing Cogeneration plant/1
Under Construction
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Post-Combustion Capture Pilot PlantChina Huaneng Beijing Cogeneration plant/2
Capture plant overall Storage tanks and heat exchangers
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Post-Combustion Capture Pilot PlantChina Huaneng Beijing Cogeneration plant/3
Rotating Equipment Assembly CO2 Purification Unit
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Providing training to Chinese engineers and scientists
Theory at Energy Centrein Newcastle
Practice at Loy Yang Power Station pilot plant
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
Our supporters
TPRI : Thermal Power Research Institute
IEA-GHG R&D programme 12 th International Post-Combustion CO2 Capture Network m eeting, Regina, 29-30 September 2009
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
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