5 post combustion capture conference kyoto, japan, 19th
TRANSCRIPT
©2018 Mitsubishi Heavy Industries Engineering, Ltd. All Rights Reserved.
5th Post Combustion Capture ConferenceKyoto, Japan, 19th September 2019
Takashi Kamijo
CONFIDENTIAL
1©2018 Mitsubishi Heavy Industries Engineering, Ltd. All Rights Reserved. CONFIDENTIAL
Outline
KM CDR ProcessTM
Advanced KM CDR ProcessTM
New KS-21TM Solvent Development
Summary
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3©2018 Mitsubishi Heavy Industries Engineering, Ltd. All Rights Reserved. CONFIDENTIAL
KM CDR ProcessTM – Features
KM CDR ProcessTM – Kansai Mitsubishi Carbon Dioxide Removal Jointly Developed by MHI Engineering & Kansai Electric Power Company (KEPCO)
Commercial proven & World’s most energy efficient Flue gas CO2 capture Technology
Proprietary hindered amine solvent “KS-1TM” with accompanying proprietary system- KS-1TM solvent with low energy, low solvent degradation & Negligible corrosion- Proprietary heat Recovering (High energy efficiency system)- Deep Amine emission Reduction system- Automatic Load Adjustment (ALAC) System
Extensive Commercial ExperiencesFor various flue gas sources such as Natural gas, Heavy oil, and Coal For variety applications: CCUS (Urea, Methanol, General, and EOR) & CCS.
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2009 India (Kakinada)450 Mt/d
52011 Pakistan340 Mt/d9
2012 India (Vijaipur)450 Mt/d
12
2016 U.S.A (Petra Nova)4,776 Mt/d
World's largest delivery of CO2 capture plant for over 100 tpd capacity; 13 plants under commercial operation and 2 under construction
7
2014 Qatar500 Mt/d
2009 Bahrain450 Mt/d
2010 UAE400 Mt/d
3
42006 India (Phulpur)450 Mt/d
8
10
22005 Japan330 Mt/d
2010 Vietnam240 Mt/d
11999 Malaysia210 Mt/d
Plant under construction
Plant under operation
13
14
6
152021 Russia1,200 Mt/d
2006 India (Aonla)450 Mt/d
2017 Japan283 Mt/d
Delivery Record of KM CDR ProcessTM
2011 U.S.A (SoCo)500 Mt/d11
16 2022 Bangladesh240 Mt/d
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World’s leading large scale post-combustion CO2 capture technology licensor
13 plants in operation and 2 under construction, from a variety of natural
gas, heavy oil, and coal flue gas sources.
2005
330 t/d Japan2009
450 t/d India
2006
450 t/d India
1999
200 t/d Malaysia
CO2 Recovery (CDR) Plant –
IFFCO Phulpur Unit (India)
2006
450 t/d India
CO2 Recovery (CDR) Plant –
IFFCO AonlaUnit (India)
2010
400 t/d UAE
2009
450 t/d Bahrain
2010
240 t/d Vietnam
2011
340 t/d Pakistan
2012
450 t/d India
2014
500 t/d Qatar
1999
210 t/d Malaysia
2016
4,776 t/d U.S.A.2017
283 t/d Japan
2021
1200 t/d Russia
Commercial Plants of KM CDR ProcessTM
2022
240 t/d Bangladesh
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Petra Nova Project
The world’s largest CO2 capture plant has been under stable operation since start-up in Dec. 2016, constantly delivering CO2 for EOR
Plant Specifications
Plant locationNRG WA Parish Power Plant(Thompsons, TX)
Project owner
Petra Nova: partnership between NRG Energy and JX Nippon Oil & Gas
Plant scale 240 MWeq
CO2 capacity 4,776 TPD (1.4 MMtonne/year)
CO2 removal 90%
CO2-EOR
Pipeline 12” diameter, ~81 miles
Injection Site West Ranch Oil Field
*U.S. Department of Energy “W.A. Parish Post-Combustion CO2 Capture and Sequestration Project Final Environmental Impact Statement Volume I” (Feb, 2013), DOE/EIS-0473
Absorber
Regenerator
Flue Gas Quencher
Cooling Tower
Flue Gas Duct
CO₂ Compressor
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New Project – under Construction
*U.S. Department of Energy “W.A. Parish Post-Combustion CO2 Capture and Sequestration Project Final Environmental Impact Statement Volume I” (Feb, 2013), DOE/EIS-0473
Client : Casale SA / Metafrax
Location: Perm, Russia
Capacity: 1,200 TPD
Feed Gas: Methanol Plant Reformer
Process : KM CDR ProcessTM
Solvent: KS-1TM Solvent
Use of CO2: Urea (Melamine) Production
Start Up: 2021
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Background & Motivation
KM CDR ProcessTM using KS-1TM is a fully commercial proven, however further reduction of CO2 capturing cost is desirable to make more CCS or CCUS projects realize.
Advanced KM CDR Process is developed as MHI’s next-generation process following after KM CDR ProcessTM technology
CAPEX: 30% reduction compared to conventional KM CDR processTM
OPEX: Lower utility consumptions (no OPEX-CAPEX tradeoffs) by new KS-21TM solvent
Commercialization is starting from new projects in the engineering stage
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Feature of Next-generation CO2 capture process
Improvement from new technology & lessons learned
• DCC and Absorber are the major cost centers (>30% of CAPEX)• Reduce height of DCC by integrating DeSOx & Quenching section and
New packing • Reduce height of Absorber by optimization based on actual operation• Reduce Regenerator diameter by 10% by selecting New packing
Technology risks are significantly reduced after large-scale unit experience
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Study scope
Absorption & Water wash
SolventRegeneration
CO2
Compression& Dehydration
Flue gas cooling(DCC)
Coal-fired power plant
Treated gas90% removal
CO2 product• 5,000 mtpd• >99.5%• 130 bar
Flue gas• 75 C• 1 bar• 11% CO2
CO2 rich KS-1
CO2 lean KS-1
Utilities• LP steam• Cooling water• Electricity• Chemicals
Scope
CO2 gasCooled flue gas
Stack
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Total CAPEX reduction
0%
20%
40%
60%
80%
100%
Conventional Advanced KM CDR Process
Re
lati
ve t
ota
l EP
C c
ost
-30%
47.8%
42.3%
9.9%
Smaller, ModularDCC & Absorber
Modular Process &Compact Layout
Reduced design margin
The Advanced KM CDR Process reduces total EPC cost by 30% and is ready for new commercial projects
Remark: The CAPEX depends on specific condition, and the above result may differ for specific project
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Approach
2014 2015 2016 2017 2018
Pilot Test with Kansai EPCO・ Solvent screening・ 1st campaign
Study activities・ Simulator development・ Laboratory campaign・ Process Optimization
2019
Pilot test with Kansai EPCO・ 2nd campaign・ Parametric test・ Optimized operation
Completed Completed
Completed
Lesson leaned from Commercial projects・ Validate Actual Operation Result・ Redundancy study
Completed
Commercialization・ Further evaluation・ Business plan・ Demo run
Ongoing & Planned
Target
30% CAPEX reduction Reduced size of towers,
design redundancy Compact layout & modular
design
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Solvent screening & Pilot test in Nanko Power Plant
Nanko CO2 Capture Pilot Plant
Location Osaka, Japan
Flue gas source Natural-gas boiler
CO2 capacity(tonne/day)
2
Tested CO2
concentration (mol%)4-20
Design capture ratio(%)
90
Configuration
Flue gas quencher
Intercooled absorber
Multipul water wash
MHI energy saving system
Potential solvents were carefully studied and a few components were selected in terms of reaction speed, VLE, corrosiveness, thermal stability, Oxidative stability, Volatility, and manufacturing cost.
A few solvent and optimized combination of component were tested by 1st and 2nd
campaigns.
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New solvent development & Features
Thermal stability• Reduce thermal degradation and allow higher stripping T and P, reducing compression
work
Oxidative stability• Potentially more tolerant to impurities • Reduce amine oxidation and HSS formation rate
Volatility• Reduce amine loss from emission and cost of water wash system• Steam consumption savings outweigh cost increases due to higher solvent circulation
Comparison of Solvent Characteristics
Parameters Relative to KS-1TM KS-1TM KS-21TM
Volatility 100 50-60
Thermal degradation rate 100 30-50
Oxidation rate 100 70
Heat of absorption 100 85
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Pilot test result – Amine emissions from absorber
0%
20%
40%
60%
80%
100%
120%
140%A
min
e c
on
to
utl
et o
f A
bso
rbe
r (
% in
pp
m)
KS-1TM
KS-21TM
KS-21TM has 50% lower amine emissions
Full-Scale FEED Study for Retrofitting the Prairie State Generating Station with an 816
MWe Capture Plant Using Mitsubishi Heavy Industries of America Post-Combustion CO2
Capture Technology – The Board of Trustees of the University of Illinois (Champaign,
IL) will complete a FEED study for the installation of a carbon capture system at the Prairie
State Generating Company’s (PSGC) Energy Campus in Marissa, Illinois. The project will
be based upon the Advanced KM CDR Process™ carbon dioxide (CO2) capture
technology from Mitsubishi Heavy Industries. The project team that successfully
completed the Petra Nova capture plant in Thompsons, Texas has been reassembled to
benefit from lessons learned. The Advanced KM CDR Process is an amine-based
capture system that uses the KS-21 solvent. If successful, the project would provide
valuable insight into lowering the cost of carbon capture systems.
DOE announced the awardAdvanced KM CDR Process™ & KS-21TM solvent
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Summary
1. World's largest delivery of CO2 Capture Plants for over 100 tpdcapacity since 1999; 13 plants under commercial operation including World’s largest operating post combustion CO2 capture plant (4,776 tpd) and 2 under construction
2. KM CDR ProcessTM can commercially apply for a variety flue gas sources of Natural gas, heavy oil, and coal for variety of CCUS; such as Urea, Methanol, EOR and other General usage.
3. Advanced KM CDR Process & New KS-21TM solvent
CAPEX: 30% reduction compared to conventional KM CDR processTM
OPEX: Lower utility consumptions by new KS-21TM solvent
Higher stability & lower volatility compared to KS-1TM.
50% lower amine emissions
Commercialization is starting from new projects in the engineering stage