WEC Italia – Cattura e Stoccaggio della CO2 (CCS)
Roma, October 18, 2011
Technologies for Carbon Capture Technologies for Carbon Capture in Oil Refineriesin Oil Refineries
Ivano MiraccaIvano MiraccaSaipem s.p.a.Saipem s.p.a.
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20112
Saipem HighlightsLeading Global EP(I)C General Contractor
Designed and built: Over 90 grass roots complexes,
1,700 process units
Over 120,000 km of land pipelines,sealines and trunklines
In the last decade, more than 100offshore EPIC projects, includinggroundbreaking deepwater achievements
Drilled over 7,300 wells of which 1,800 offshore
Distinctive ‘frontier focus’ inOil & Gas industries
Full service EP(I)C provider
Key local employer and investorin strategic markets
Most modern, technologicallyadvanced offshore construction fleet
High quality drilling player onshore and in niches offshore
2010 Revenues 11.2 B€ End-of-2010 Backlog 20.5 B€
40,000 employees, of which 7,000 Engineers & Project Managers
Operating in more than 70 countries,more than 50 permanent establishments,employees from 122 nationalities
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20113
Saipem Experience on Carbon Capture and Sequestration (CCS)
SAIPEM has substantial know-how and experience in the entire CO2 capture, transportation and storage chain acquired providing engineering services to Eni and other O&G companies.
• Pipelines design & construction.
•Environmental impact studies.
• Geomechanical modelling and monitoring
• Well and reservoir modelling, • Environmental and wellbore
integrity monitoring• Environmental impact studies
StorageStorage:
CaptureCapture:• Post combustion (CO2 washing)• Pre combustion (Steam reforming/gasification)• Oxy-firing (Oxygen combustion)• Environmental impact studiesTransportatioTransportationn:
SourceSource
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20114
Presentation Summary
Power Station vs. Refinery
Refinery Emission Sources
CO2 Capture in the FCC unit
CO2 Capture in Hydrogen Production
CO2 Capture in Crude Heaters and Steam Boilers
Overall approach
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20115
Power Station vs. Refinery
Power Station vs. Refinery
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20116
A sense of scale
Power stations are responsible for about 80% of CO2 emissions from stationary sources more than 10 billion tons/year
Refineries are third (after cement production) with about 6% of emissions (0.8 billion tons/year)
This justifies current focus on power production Pressure of law-makers concentrated on power production. At the GHGT-10 conference >90% of capture work was related to capture in
coal-fired power stations
800 MW NGCC Power Station ~ 2.8 MTPY of CO2 500 MW Coal Power Station ~ 3.5 MTPY of CO2
Refinery processing 250,000 bpsd of crude ~ 4.5 MTPY of CO2
Emission for a refinery vary for different crudes, fuels and configuration
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20117
Different issues and concerns
POWER STATION REFINERY
Single Source Multiple sources (20 or more stacks )
Fixed CO2 Concentration (4% for NGCC – 12% for coal)
CO2 Concentration variable with source and feedstock
Very fast and drastic changes in workload may be required
Capture operation of the same type than usual refinery operation
Plot plan availability is not necessarily a concern
Plot plan availabilty is a key concern
Additional safety issues mainly related to use of chemicals
Additional safety issues mainly related to use of pure oxygen
CO2 capture introduces new types of processes inside the power
station
Already includes process units using the same techniques than
capture units
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20118
Refinery Emission Sources
Refinery Emission Sources
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 20119
Emissions vary for different crudes and refineries
LOW EMISSION REFINERY HIGH EMISSION REFINERY
100,000 BPSD LIGHT CRUDE 100,000 BPSD HEAVY CRUDE
No cracking – No sulfur reduction Complex refinery with many different products
Fuel: Natural Gas Fuel: Fuel Oil
Few Heaters & Boilers (< 12) Many Heaters & Boilers (> 50)
No Hydrogen production Hydrogen production
GHG emissions: < 1.2 MTPY GHG emissions: > 4.8 MTPY
Source: ExxonMobil (2008)
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201110
Refinery Carbon Sources
SMR Heaters Co-GenFCC
Regen
Fuel
Reformer Feed
Flue Gas Flue Gas Flue Gas Flue Gas
Air
Two major emitters
CCS will mostly be retrofit, with plot space issues
Multiple capture technologies likely needed
Some easy CO2 but not a lot, since pure CO2 vents from hydrogen plants are disappearing as new PSA-based SMRs are built
Emerging resource (e.g. heavy oil) have larger carbon footprint and will increase emissions.
Power Steam
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201111
Typical distributions of emissions
10-15% of emissions are caused by fuel combustion for power generation
35-45% of emissions are caused by fuel combustion in process heaters (furnaces) and steam boilers
30-50% of emissions are single source from chemical units , depending on the refinery process scheme:
Renerator of the Fluid Catalytic Cracking unit for FCC-based refineries
Hydrogen production unit for hydrocracker-based refineries
FCC AND HYDROGEN MAIN SINGLE TARGETS FOR SUBSTANTIAL REDUCTION OF GHG EMISSIONS IN A
REFINERY
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201112
CO2 Capture in the FCC unit
CO2 Capture in the FCC unit
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201113
Overview of an FCC unit
RISER
Products- Gasoline- LPG- Propene
Feed- VGO- ATRSteam
Air
REGENERATOR
Flue gas
10 – 20 % CO2
A unit processing 60,000 bpsd emits ~ 1,000,000 t/year of CO2
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201114
Main technological options
A – Waste Heat BoilerB – SOx scrubberC – Amine UnitD – CO2 compressorE – Dehydration (mol. sieve)F – ASUG – Recycle compressor
Flue-gas A B C D
E
Amine Absorption
CO2
Flue-gas A B
F
D
E
G
99.5% O2
Oxy-combustion
CO2
Recycle
Equipment list
> 99% pure90% recovery
96% pure>99 % recovery
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201115
Some comparison among options
Energy consumption is higher for the post-combustion case (typically 2.5-3.5 GJ/ton vs. 1.5-2.5 GJ/ton)
Capital cost is higher for oxy-firing, mainly due to the cryogenic separation (Petrobras, 2008).
CO2 avoidance cost is potentially lower for oxy-firing (Petrobras, 2008)
Post-combustion requires plot plan close to the FCC unit (order of 50x50m). Oxy-firing does not, if 96% CO2 purity is acceptable
Surely not acceptable for EOR (oxygen is the main impurity)
Oxy-firing requires safe location for air separation unit and safety measures for pure oxygen piping.
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201116
The CO2 Capture Project (www.co2captureproject.org) is undertaking a field demonstration of FCC regenerator oxy-firing with flue gas recycle.
Tests are taking place at a large pilot unit (33bbl/d of feed) at a Petrobras research complex in Parana state, Brazil.
Main goals of the project are: Test start-up and shut-down procedures Maintain stable operation in oxy-combustion
mode Test different operating conditions and process
configurations Obtain reliable data for scale-up
Source: Project Fact Sheet (www.co2captureproject.org)
The CCP Oxy-combustion FCC Demonstration Run
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201117
CO2 Capture in hydrogen production
CO2 Capture in hydrogen production
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201118
Steam Methane Reforming
SMRWater Gas
ShiftH2 Purification
(PSA)
NaturalGas
Flue Gas ~ 765 kg CO2/ 1000 Ncu ft H2
Feed
Fuel
Steam
Hydrogen product – 99.9+% purity
Low energy usage compared with previous conventional design (MDEA washing)
All CO2 emitted in the flue gas – low partial pressure- even though ~ 60% is generated inside the process at high pressure
Post-combustion only option with this scheme
AirTail gas
Product
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201119
Autothermal Reforming
Syngasgeneration
Water-gasshift
CO2removal
Fuel H2, COCO2, H2O
H2, CO2 H2
CO2H2O
O2
H2O
AirSeparation
Air N2
For large volumes, autothermal reforming (ATR) is generally lower cost than SMR.
For a CO2 constrained enviroment ATR is always lower cost when capture is required.
CO2 avoidance cost 50% lower for ATR/MDEA vs. SMR/PSA
SMR/MDEA avoidance cost is 30% lower than ATR/MDEA, but only process side CO2 is captured (source: Chevron,2008)
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201120
CO2 Capture in process heaters & boilers
CO2 Capture in process heaters & boilers
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201121
A large percentage of refinery CO2 emissions are generated by the combustion of fuel gas or fuel oil in crude heaters and steam boilers
In a world-scale refinery this emission source may account for more than 2 million tons/year.
Heaters & boilers are widely scattered in size and in refinery location.
Usually a few tens of units, but may be more than 50. May discharge to ten or more stacks located in different zones A single unit may roughly emit from 50,000 to 500,000 tons/year CO2 concentration in flue gas ranging from 4 to 10% vol., depending on
the fuel used
CAN THIS SOURCE BE MITIGATED?
Heaters & Boilers: a peculiar source of CO2
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201122
POST-COMBUSTION Very large and long ducts should be constructed to convey all of the
effluents to a centralized post-combustion unit Alternatively several smaller units should be built close to each stack. Cost and lay-out considerations seem to preclude this approach.
PRE-COMBUSTION All of the fuel could be conveyed to a single large-scale ATR unit, producing
hydrogen to be used as fuel for all heaters & boilers No plot space needed near the existing units Retrofit of heaters and boilers may be needed for hydrogen burning.
OXY-FIRING Today a single train of cryogenic air separation may produce up to 4000
tons/day of oxygen, roughly corresponding to 1 MTPY of emitted CO2 Part of the flue gas (> 50%) would be recycled to each unit for combustion
temperature control Air in-leakage would lead to low CO2 purity (~ 80%) making a purification
step necessary before transportation and storage need for local or centralized plot plan
Retrofit of heaters and boilers may be needed for oxy-combustion.
Capture techniques applied to Heaters & Boilers
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201123
Overall approach to carbon capture in the refinery
Overall approach to carbon capture in the refinery
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201124
The Hydrogen-fired refinery
Heaters Co-GenFCC
Regen
Air
Power Steam
ATR Water-gasshift
CO2removal
Fuel H2, COCO2, H2O
H2, CO2
CO2H2O
O2
H2O
AirSeparation
Air N2
Flue Gas
Hydrogen
CO2-free gas to stack
To hydrotreating
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201125
Gas turbines may only burn fuels containing up to 50% of hydrogen Nitrogen from air separation may be used as diluent Advanced burners for 70-85% concentration are under
development and should be available commercially by 2020.
According to vendors, single line ATRs may be built up to about 500,000 Nm3/h of hydrogen. That would be enough for several refineries. Two parallel lines might be alternatively used.
Hydrogen burning in boilers and heaters is technically feasible, but needs to be demonstrated at the tens of MW scale before commercial implementation.
Current limitations to an hydrogen-fired refinery
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201126
The Oxygen-fired refinery
SMR Heaters Co-GenFCC
Regen
Fuel
Reformer Feed
Power Steam
ASUAir Nitrogen
Oxygen
Flue gas
O2
Flue gas
CPUCO2
Flue gas
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201127
The oxygen-fired refinery would only mitigate FCC, heaters and boilers emissions.
Hydrogen production and power generation would need separate capture
2-4 parallel air separation trains may be needed FCC regenerator oxy-firing still needs to be proven Oxyfiring of boilers already at the demo stage (30 MW)
Oxyfiring of heaters still needs a dedicated development program
Current limitations to an oxygen-fired refinery
Technologies for Carbon Capture in oil refineries Roma, Oct. 18, 201128
The Complete Environmental Services The Complete Environmental Services ProviderProvider
THANK YOU FOR YOUR ATTENTIONTHANK YOU FOR YOUR ATTENTION
Top Related