doosan power systems post combustion carbon capture technology development dr saravanan swaminathan...

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Doosan Power Systems

Post Combustion Carbon Capture Technology Development

Dr Saravanan SwaminathanNov 3, 2012

International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS Experiences

2Doosan Power Systems© Doosan Power Systems 2012

Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A


Products and Services

Doosan Power SystemsCEO JM Aubertin

Turnover 2011: £800mEmployees: 5,800

Doosan BabcockDoosan Lentjes Skoda Power Doosan Babcock

Boiler & Air Pollution Control Turbogenerators Plant Service

Doosan Heavy Industries

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Outline

Introduction







Concluding remarks

Q&A


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Background - CO2 Emissions, Global Primary Energy Demand

Use of coal will continue to grow and is necessary to meet the energy needs of developing countries and to secure supplies of developed countries

200 years of proven reserves

Coal is sourced from many stable countries around the world and is key to security of supplies

(Source: IEA – World Energy Outlook 2011)


Indian Power Sector Outlook Plan

22

67

86

119

150

203

24

76

104

151

197

275

0

50

100

150

200

250

300

10th plan'02-'07

11th plan'07-'12

12th plan'12-'17

13th plan'17-'22

14th plan'22-'27

15th plan'27-'32

8% GDP growth 9% GDP growth

Cap

acit

y A

dd

itio

n R

equ

ired

(G

W)

Capacity Addition vis a vis GDP Growth

REGION THERMAL Nuclear HYDRO R.E.S.@ TOTAL

COAL GAS DSL TOTAL (Renewable) (MNRE)

Northern 29,923.50 4,671.26 12.99 34,607.75 1,620.00 15,423.75 4,437.65 56,089.15

Western 42,479.50 8,254.81 17.48 50,751.79 1,840.00 7,447.50 8,146.69 68,185.98

Southern 23,032.50 4,962.78 939.32 28,934.60 1,320.00 11,338.03 11,769.32 53,361.95

Eastern 22,337.88 190.00 17.20 22,545.08 0.00 3,882.12 410.71 26,837.91

N. Eastern 60.00 824.20 142.74 1,026.94 0.00 1,200.00 228.00 2,454.94

Islands 0.00 0.00 70.02 70.02 0.00 0.00 6.10 76.12

All India 117,833.38 18,903.05 1,199.75 137,936.18 4,780.00 39,291.40 24,998.46 207,006.04

Installed Capacity in MWe

Anticipated capacity addition at completion of 11th plan – 71,644MWe

Proposed capacity addition during 12th plan is 75,785MWe in line with 9% GDP growth

Target capacity addition by 2030: 550 – 750 GW from present Level of 207 GW

Source: “All India region-wise generating installed capacity (mw) of power utilities”, Central Electricity Authority (www.cea.gov.in) as of 31/08/2012“Report of the working group on power for Twelfth Plan (2012-17)”, Ministry of Power, Government of India, New Delhi, Jan 2012


Growth of Power Generation in India (2011-2012)

Note:Generation excludes generation from plants up to 25 MW Capacity1 BU = 1 Billion Units or 1 Billion kWh

En

erg

y G

ener

atio

n (

BU

)

Source: “Operation performance of generating stations in the country during the year 2011-12”, Central Electricity Authority, New Delhi, April 2012

Total annual power generation growth of 8.05% – highest during the decade.

Remarkable growth in nuclear generation of 22.86% – improved availability of nuclear fuel to the nuclear plants.

Improved hydro power generation of 14.15 % – good monsoon

Total thermal generation growth of 6.53 % – growth rate of 9.20 % over last year

Growth of thermal generation was mainly restricted by: coal shortages receipt of poor quality/ wet coal low schedule from beneficiaries increased hydro generation increased nuclear generation


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Background - CO2 Emissions

Fossil fuel power generation needs to be much cleaner to meet CO2 targets

IEA 2011 Energy World Energy Outlook


Outline

Introduction







Concluding remarks

Q&A


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CO2 Reduction Strategies

Two track approach– Power plant efficiency

improvement– Carbon dioxide Capture and

Storage (CCS)

Approaches are fully complementary

Power plant efficiency improvement is available now using supercritical boiler/turbine technology

CO2 Capture is under development

CCS can be retrofitted to PF fired plant

Both approaches are necessary on the route towards zero emissions

CO2 Reduction

Track 1 :Increased Efficiency,Biomass co-firing, etc.

Track 2 : Carbon Capture& Storage (CCS)

Possible Now

Longterm

TimeMediumterm 2010 2020

-25%

Baseline

- 35%

- 95%


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1960 1980 2000 2020

35

40

45

50

55

30

Supercritical Boilers

Sub Critical Boilers

Plant efficiency

% NCV

Year

Target AD700

50 – 55%

Doosan Power Systems

ASC

46%

Meri PoriHemweg

New Chinese Orders

42%

Chinese fleet 38%

OlderPlants

Increasing Efficiency

Lower CO2

emissions

38%

32%

UK

fleet

Abatement of CO2 by Efficiency Improvement of Pulverised Coal Plant

(-23%)

(-29%)

Best Available Advanced Supercritical Technology being supplied now

E.On 50+ project at Wilhelmshaven suspended


Outline

Introduction







Concluding remarks

Q&A


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CO2 Capture Technologies

There are three main pathways to the capture of CO2 from coal-fired power generation


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Numerous studies have shown that these technologies are similar in terms of process efficiency achieved and cost of electricity.

No clear winner, but Post Combustion Capture and/or Oxyfuel will need to be retrofitted to plants currently being built around the world

All three capture technologies have been proven in pilot plants, but need scale-up and demonstration on full-size plants

CO2 Capture Options for Near Zero Emissions Coal Power Plant

Three options for commercialisation by 2020

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Post Combustion Carbon Capture

Leading Edge Technology


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Post Combustion Capture Technology – Solvent Scrubbing

Solvent Scrubbing, also known as “sweetening” or acid gas removal, was originally developed to remove H2S and CO2 from methane in natural gas processing plants and other industries.

Driven by the concerns of the impact of rising CO2 emissions from fixed sources, there has been significant interest in the development of CO2 capture from Pulverised Coal Flue Gas.


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Post Combustion Capture Technology – Solvent Scrubbing (Amine)

Flue Gas

Blower Cooler

ABSORPTION COLUMN

Water Wash

Demister

Offgas

Solvent Cooling

Make-up Solvent

Lean/Rich Exchanger

REGENERATION COLUMN

Reflux Vessel

Condenser

CO2 to Compression &

Dehydration

Reboiler

LP Steam

LP Condensate

~50°C

~40°C

~120°C

~125°C

~45°C

mixedN2 / CO2

N2CO2

Amine Scrubbing: R → Alkyl group


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PCC Technology: Summary

Advantages

Uses existing power plant technology

Can be retrofitted to existing plant or installed on

new build

Demonstrated at small-scale in other industry

sectors

Can be designed to fire a wide range of fuels

Robust to changes in fuel quality


Outline

Introduction







Concluding remarks

Q&A


Doosan Carbon Capture Technologies

25 years of experience in carbon capture

2008 2009/10 2012/16 2016/20171987 20032000 2008 2009/10 2012/16 2016/20171987 20032000

Post Combustion Capture (PCC)

University of Regina development of PCC

Boundary Dam PCC donated to University for research

UoR’s ITC completed

Doosan invest into HTC Purenergy taking 15% & exclusive rights to PCC technology

ERTF converted to PCC Test Facility

Antelope Valley FEED & Ferrybridge Demo

Large Scale Power Plantwith CCS

Commercial CCS Market

160KWt at Doosan ERTF

Oxyfuel

1996 2009 20202012/1420081996 2009 20202012/142008

ERTF OxyfuelConversion

40MWt OxyCoalTM

Burner at Doosan CCTF

Full Power Plant Demo Expected100-250MW

Forecast to be fully commercialised by 2020

1992


Technology Leaders

Global licensee of HTC Purenergy technology developed in conjunction with the University of Regina (UoR)– Over 20 years CCS experience– Laboratories for development of solvent, material and process.

Advanced designer solvent (RS family) providing:– High efficiency system – Low degradation rates– Tailored to meet operating and flue gas conditions

Patents in place for high efficiency advanced solvent and steam-side plant integration

Scale-up validated against actual operating data from several plants as large as 800 t/day (with +/- 3% accuracy)

Scale-up only achievable through a complete and thorough understanding of:– All physical and chemical properties (kinetics, diffusivity, etc.)– Operating conditions– Proper application of numerical modeling tools

Optimised process design (TKO™)

Heat integration

Reduction in steam

Advanced solvent, advanced process and optimised integration provide maximum customer value

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22Doosan Power Systems© Doosan Power Systems 2012 22

Solvent Supply and Management

Ability to optimise process to match solvent specification in-house ensures complete system optimisation and compatibility

On-line monitoring and solvent management

Huntsman is our global strategic partner and can provide long-term aftermarket supply of optimised solvents

No mandatory long-term solvent tie-in, Client has flexibility to meet their own needs or go to market

Screen shot: online plant monitoring

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Screen Shot of MCC Network control system

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Screen Shot of MCC Network control system

Most economic and flexible approach, but with infrastructure to support for the long-term


Test Facilities and Demonstration Projects

Facilities and technology create a winning edge

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20+

yea

rs o

f d

emo

Ind

ust

ry s

cale

ERTF, 1 t/day Commissioned in 2010 Ability to test wide range

of coals and other fuels High degree of flexibility

and accuracy to test wide range of solvents and other modifications

Ferrybridge, 100 t/day Largest post carbon capture

demonstration plant in the UK Long-term testing and

validation of process and solvent performance

Evaluate transient conditions and process control

Extensive monitoring planned

Boundary Dam, 4 t/day Commissioned in 1987 Dedicated to post-combustion

capture since 2000 Captures CO2 from flue gas

emitted from lignite-fired boiler Upgraded in 2007 to evaluate

advanced process with RS-2

ITC, 1 t/day Opened in 2003 Flue gas from natural

gas combustion Includes equipment to

study corrosion, material selection, solvent degradation and kinetics

Performance demonstrated on wide range of fuels and different plant configurations


Emissions Reduction Test Facility

Emissions Reduction Test Facility (ERTF) for PCC Solvent Scrubbing – A 160kW t combustion test facility

Capable of firing a very wide range of coals or natural gas.

Originally constructed to test primary NOx reduction measures, subsequently adapted and upgraded to test secondary NOx reduction measures.

Upgraded for oxyfuel operation as part of the OxyCoal-UK: Phase 1 project – a collaborative project sponsored by the UK Government with industrial and academic participation.

Post-Combustion CO2 Capture and Flue Gas Desulphurisation (FGD) installation completed in 2010.

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Emissions Reduction Test Facility

PCC Solvent Scrubbing Process - Equipment

Absorber column 10” NB (DN250) 4-off packed bed sections (with multiple

solvent feed inlet points)

Stripper column 8” NB (DN200) 4-off packed bed sections

Water Wash Column 8” NB (DN200) 1-off packed bed section

Heat exchangers Gasketed (plate and frame)

Pumps Duties met by triplex diaphragm pumps

for high head – low flow duties Variable speed drives for efficiency and

ease of control

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Emission Reduction Test Facility PCC Plant - Coal Flue Gas Testing

RS-2TM solvent< 1.2kg steam/ 1 kg CO2 captured, which equates to less than 2.5 GJ/t CO2 captured

Competitive CO2 capture efficiency and regeneration performance demonstrated on coal flue gas

Capture Rate (%)

Steam Duty (kg/kg)

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/kg

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Emissions Reduction Test Facility PCC Plant - Simulated CCGT Flue Gas Testing

CO2 capture efficiency and regeneration performance demonstrated on simulated CCGT flue gas

RS-2TM solvent< 1.4kg steam/ 1 kg CO2 captured, which equates to less than 3.0 GJ/t CO2 captured

Capture Rate (%)

Steam Duty (kg/kg)

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(kg

/kg

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Emissions Reduction Test Facility PCC Plant

Next steps:

Carry out off-gas emissions measurement and control trials

Continue to optimise the process

Reduce solvent regeneration energy consumption

Support for commercial bids:– Capturing carbon dioxide from coal and natural

gas flue gas – diverse product offering

– Test materials and techniques to reduce capital and operational expenditure on larger scale plant

– Demonstrate plant functionality and flexibility to clients


CCPilot100+ Ferrybridge


Ferrybridge CCPilot100+

PCC demonstration plant using DPS’ technology

100 t/day slip stream from a 500MWe unit on SSE’s Ferrybridge Power Station, making it the largest PCC demonstration in the UK

Two year test programme, fast-tracked build, operating March 2012

Funded by all the project partners

Lessons learned to be incorporated into future designs


CCPilot100+ Project Location

Pictures courtesy Google Earth


Complementary R&D Projects

1. Techno-Economic Optimisation A steady-state HYSYS model (calibrated with real data) combined with an economic model to be used for design and cost optimisation.

2. Analysing Degraded solvent Use of various analytical techniques (GC-MS, LC-MS, HPLC-RID) to characterise degraded solvent and identify preferred techniques for analysis

1. Amine Waste Water TreatmentCharacterisation of waste water streams from CCPilot100+ and identification of alternative waste water treatment methodologies

1. COMCATBuild and site test a novel monitoring apparatus that utilises a unique combination of well known instruments to monitor solvent loading in real time

2. TRACTION Use a dynamic model to investigate operation at transient loads to suit market demand for flexibility.

1. Amine Degradation Product ModellingAdapt an existing kinetic chemical reaction model for atmospheric amine degradation product emissions and calibrate it with actual plant measurements to predict solvent degradation products.


Wider Academic Involvement

One-Month Secondments ( 24 Students )– From Edinburgh, Leeds, Nottingham, Sheffield and Imperial College– Aimed at MSc / PhD / Eng Docs who will complete an additional on-site project to further their

understanding of CCS and the as-built CCPilot100+ plant

Industrial Awareness Module ( ~40 Students )– From Edinburgh, Leeds, Nottingham and Sheffield– 1 week split between Renfrew and Ferrybridge focused on process safety and deployment of

CCS.

1 Day Visits ( >400 students, ~14 Visits) – From Edinburgh, Leeds, Nottingham, Sheffield, Imperial College, York, Durham, Lancaster,

Manchester and Newcastle– Lectures on the power station and electricity generation and the PCC process, its

commercialisation and economic drivers

5 day short course on CCS via the Continuing Professional Development (CPD) Unit at University of Leeds and as a 10-credit MSc course at University of Strathclyde

Other industrial and research organizations are being invited (and requests being considered) to visit the CCPilot100+ during operation.


Simulation & modelling

CCPilot100+ Project Execution

Testing program

P&IDs & engineering

Column fabrication & deliveryConstruction

3D modelling

Current stage


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CO2 capture rate and product compositions

Steam consumption at re-boiler Amine and degradation product atmospheric emissions Absorber column efficiency

– Column CO2 composition and temperature profiling

Power and water consumption under differing operating regimes Use different process configurations to optimise thermal

integration Solvent testing and formulation for efficiency and durability Performance of construction materials including polymers Comparison of performance with other pilot plant for scale-up

CCPilot100+ Test Programme Key Parameters


Process Measurement & Control - CCPilot100+

Gas and solvent flow rates, temperatures and pressures

On-Line Gas Analysis– FTIR – Extractive multi-point heated sampling system– Ammonia Tuneable Diode Laser – Cross-duct, non-

extractive– ppm Oxygen Micro-Fuel Cell – Extractive cold sampling

system

Manual Gas Analysis– FGD Polisher Performance– PCC – Based Emissions

– Solvent Carryover– Degradation Products

Process conditions and gas analysis


On-Line Solvent Analysis– Solvent Concentration – On-Line Titration

– CO2 Loading – On-Line Titration

Off-Line Solvent Analysis– Solvent Composition – Ion Chromatography– Solvent Concentration - Titration

– CO2 Loading – Titration and Gas/Liquid Displacement

PCC Chemistry Lab in Renfrew – Lab-Based Degradation Trials– Jacketed reactor used to run long-term

degradation trials simulating both coal and gas firing via control of CO2 and O2

Solvent analysis – Major Parameters

Process Measurement & Control - CCPilot100+


CCPilot100+ Current Status

Commissioned to run on MEA

Plant handed over to SSE Operations Group on 22nd March 2012

1000 hours of running time recorded to date on 30% MEA with water. Plant optimisation on-going.

UK Environment Agency and SSE interface

– positive dialogue

– supportive of emissions measurement & control to develop standards during the test programme


CCPilot100+ MEA Test Results

MEA preliminary results show good agreement with publically available test data– typical quoted values of 3.6 to 3.9 GJ/t CO2

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CCPilot100+ Operating Experience

Good working relationships developed with– SSE Ferrybridge Station and CCPilot100+ staff

– Environment Agency

– Main process plant item suppliers

– C&I equipment suppliers

– Analytical instrument suppliers

Commissioning– Development of analytical techniques

– On-line solvent analysis instrumentation

Testing– Selection of manual gas analysis contractor

– Liaison with Environment Agency

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Cost Reduction - PCC Materials

Installation Cost (i.e. raw material cost + fabrication cost)

– must be competitive in relation to ‘standard’ construction materials (e.g. carbon steel, concrete)

– must be site-friendly and not too labour-intensive

Operating Cost (i.e. degree of process interaction)

– minimize material losses due to corrosion/degradation (repair outages)

– minimize contamination of PCC solvent (solvent make-up reagent and/or outages)

– minimize fouling of surface (cleaning outages)

Track Record (i.e. perceived level of commercial risk)

– preferably in PCC or in amine-based natural gas purification

– composite track record from several related industries may be acceptable

– demonstration may be required (difficult due to the risk to the project)

In theory, cost reduction is the single biggest driver

In practice, track record has historically dominated pilot-stage materials selection


PCC materials testing

Materials Selected Stainless steels Duplex alloys Solid polymers Structured polymer

composites Polymer-based coatings

All on test at CCPilot100+ in the harshest survivable environments on the plant

Full suite of construction/application procedures

Further industrial-scale trialling


2nd Generation PCC Technologies

Technology Brief Description Potential Benefits vs 1st Gen Perceived Cons

Solid sorbents

Monolithic structures using low temperature swing adsorbents

< CAPEX/OPEX, and < energy penalty Potentially limited to gas-fired plants due to poisoning by contaminants in coal flue gas

High temperature swing adsorbents – Calcium looping

< CAPEX and < energy penalty High attrition, poisoning of the sorbent, > OPEX

Immobilized amines

Immobilized amines – looping technology

Electrical swing adsorption < CAPEX > OPEX, > Energy penalty, unclear regeneration process

Advanced Liquid Solvents

Ionic liquids (IL) (incl. amino acid salt solutions)

Non-toxic solvent, low solvent carryover due to low vapour pressure and environmentally safe

Expensive, > OPEX due to multi-step regeneration, And scale-up difficulties

Amine-based solvents Well developed technology and many demonstrations underway

> CAPEX/OPEX, environmental concerns, limit on minimizing energy penalty

Aminosiloxanes-based solvents Low solvent carryover due to low vapor pressure

Non-aqueous solvent – problems with condensed moisture

Enzyme-promoted K2CO3

solventsNon-toxic solvent, Low temperature regeneration

Low temperature stripping (ultrasonic stripping being developed)

MembranesHollow fibre membranes No moving parts,

no reagent usage andlow footprint (for Metal organic frameworks)

Membrane integrity, > OPEX,mechanical stability through use of support structures, particulate blocking/poisoningNanocomposite/ Nanostructured polymeric

membranes

Cryogenics Chill flue gas to condense and separate CO2 < CAPEX Higher parasitic power, > OPEX


Monolithic Structures Using Low Temperature Swing Solid Sorbents

Objectives: Development of InvenTyS’ VeloxoTherm™ technology (based on a Temperature Swing adsorption process) using a proprietary structured sorbent in a rotating frame (similar to regenerative air heaters used in power plants) for NGCC PCC applications

Potential Benefits: A proven technology with a demonstrated reliability and simplicityEnvironmental: Low levels of waste water generatedOPEX : (i) Lower regeneration energy (< 50% of the conventional amine process) and (ii) High sorbent lifecycle (reducing replenishment costs)CAPEX: (i) Low footprint due to integrated design of the adsorber and stripper into a Rotary Adsorption Machine (RAM)

Project Partners: InvenTyS, Howden, Rolls Royce, MAST Carbon and Doosan Power Systems


Enzyme Activated K2CO3 Process with Ultrasonic Regeneration

Objectives: An integrated bench-scale PCC system that combines the attributes of a bio-renewable enzyme catalyst with low-enthalpy absorption solvent and novel ultrasonically-enhanced regeneration system

Potential Benefits:Environmental: Benign solvent leads to low emissions and degradation productsOPEX : Low, (i) Enzyme is not susceptible to degradation by other flue gas components such as SO2, O2 etc and (ii) Lower regeneration energy (< 50% of the conventional amine process)

CAPEX : Low, (i) Lower operating temperatures and relatively non-corrosive solvent allows the use of less expensive materials (ii) No FGD polisher needed due to enzyme’s resistance to SOx in the flue gas, however a suitable HSS removal methodology will be adopted

Project Partners: Novozymes North America, Pacific Northwest National Laboratory, University of Kentucky and Doosan Power Systems


Next Steps

Pursue large demonstration projects CCPilot100+

– Run RS-2™ testing – Q4 2012– Advanced solvent testing - through 2013– Advanced PCC materials testing through

2012 and 2013– On-line liquid & gas analyses throughout

test programme ERTF

– Off-gas emissions measurement and control

– Continued process optimisation– Support commercial bids

Solvent Development– Performance assessment– Degradation characterisation

Feasibility studies & pilot-plant scale demonstration of 2nd generation PCC technologies


Front End Engineering Design (FEED) Studies

Application of the process technology to real projectsC

oal

-Fir

ed B

oile

rsN

GC

C

Flue gas type: NGCC exhaust Full flue gas processing of a

single 230MWe gas turbine Ultra low pressure drop

design Feasibility study completed

2011

Flue gas type: coal-fired flue gas Four oil-fired gas boilers being

converted to bituminous coal-firing

Competing for NER 300 funding FEED completed Q2 2011

CO2 from the adjacent Dakota Gasification Company (~3.0 MTPY) is sold for enhanced oil recovery

FEED completed November 2010

Flue gas type: NGCC exhaust

Configuration: two absorbers and one stripper

FEED completed 2009

Basin Electric, AVS, 3,000 t/day ENEL, Porto Tolle, 4,200 t/day

Statoil Karsto, 3,000 t/day SSE, Peterhead, 3,300 t/day


Emissions reduction test facilities

1 t/day to 4 t/day CO2

Slipstream

100 t/day CO2 ≈ 5MWe

Ferrybridge

Large demonstration project(s) slipstream

~3000 t/day CO2 ≈ 150MWe

Commercialisationfull-scale plant

10,000 t/day CO2 ≈ 500MWe

15,000 t/day CO2 ≈ 800MWe

Doosan Power Systems Post Combustion Roadmap

2012


Outline

Introduction







Concluding remarks

Q&A


50

Safety Issues - CO2

Most of plant will operate under suction But from FGR fan through to the

windbox / burners the system is under pressure, and may leak

CO2 is denser than air and will collect in low level confined spaces i.e. in the basement areas Buoyancy helps dispersion

Good ventilation is essential How do you ensure this? Would you trust your life to a CFD

model?

The Dangers of Carbon Dioxide

1000ppm 0.1% Prolonged exposure can affect powers of concentration

5000 ppm 0.5% The normal international Safety Limit (HSE, OSHA)

10,000ppm 1% Your rate of breathing increases very slightly but you probably will not notice it.

15,000ppm 1.5% The normal Short Term Exposure Limit (HSE, OSHA)

20,000ppm 2% You start to breathe at about 50% above your normal rate. If you are exposed to this level over several hours you may feel tired and get a headache.

30,000ppm 3% You will be breathing at twice your normal rate. You may feel a bit dizzy at times, your heart rate and blood pressure increase and headaches are more frequent. Even your hearing can be impaired.

40,000-50,000ppm 4-5% Now the effects of CO2 really start to take over. Breathing is much faster - about four times the normal rate and after only 30 minutes exposure to this level you will show signs of poisoning and feel a choking sensation.

50,000-100,000ppm 5-10% You will start to smell carbon dioxide, a pungent but stimulating smell like fresh, carbonated water. You will become tired quickly with laboured breathing, headaches, tinnitus as well as impaired vision. You are likely to become confused in a few minutes, followed by unconsciousness.

100,000ppm-1,000,000ppm 10-100% Unconsciousness occurs more quickly, the higher the concentration. The longer the exposure and the higher the level of carbon dioxide, the quicker suffocation occurs.

15 minutes

8 hours

Can we be sure that we will never exceed safe levels of CO2?


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PCC Challenges

There is, at present, commercial risk associated with CO2 capture in general:

Technical– Process Design and Chemistry– Scalability– Materials Selection

Environmental– Emissions from the PCC plants, their characterisation, impact and mitigation

Social

Financial

Legislative


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Technical Challenges – Process Design and Chemistry

PCC process design depends on the characteristics of the flue gas, solvent and the required CO2 capture efficiency.

The following are typical characteristics of flue gas from coal-fired power plants– High volume flow rates

– Low CO2 concentration (~15% v/v for coal power plants, and ~4% v/v for gas plants)

– Low gas pressures

The baseline design of CO2 capture plants above or equal to 90% carbon capture efficiency represents the final objective. This, however, is to be achieved at very low capital and operational costs for the technology to be competitive.

Capital Costs: Represent the cost of the plant equipment & components: Absorber, stripper, pumps, heat exchangers etc.

Operation Costs: Solvent life, Parasitic losses including steam for solvent regeneration


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Because process design is an iterative process, advanced simulation capabilities need to be developed. These can be a mixture of commercially available and in-house (proprietary) process simulators

Commercial process design tools used by technology developers; Aspen Plus ® Aspen HYSYS® ProTreat® ProMax ®

Simulation software models need to be evaluated for their performance prediction before they can be used for designing large-scale plants.


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Accurate estimation of process parameters for Process Design is the key!

Equilibrium concentrations – Thermodynamics

Enthalpies of formation of the components – Standard databases – Scarcity of data for alkanolamine ions

Estimated using equilibrium constants data – Measured temperature ranges

Heat exchanger design fundamental parameters– Fluid mechanics (geometry, fluid velocity)– Fluid properties (density, viscosity, thermal conductivity, specific heat capacity) – Heat transfer coefficients


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Technical Challenges – Scalability

One of the major challenges is the ability to scale carbon capture plants to large power plant capacity (>500 MWe) within reasonable cost and footprint.

For sizing a full-scale power plant (>400 MWe), realistic assumptions on the size of equipment, the foot-print and the technical complexity in terms of equipment integration and construction required to achieve 90% capture should be considered.

ERTF CCPilot100+ Basin Electric

Plant Capacity (tpd) 1 tpd 100 tpd 3000 tpd

Plant Size 160 kWt 5 MWe 125 MWe

PCC Design Gas Flow (kg/h) 230 28, 245 700,346

CO2 capture (%) 90% 90% 90%

CO2 Absorber Dimensions (dia x height: m) 0.25 x 9 2.3 x39 11.8 x 45.4

Stripper Column Dimensions (dia x height: m) 0.20 x 8 1.1 x 30.5 5.5 x 30.5


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Technical Challenges – Material Selection

Commonly used SS grades have a high cost/tonne.

Certain SS grades are also susceptible to Stress Corrosion Cracking (SCC) at higher

temperatures.

Certain SS grades can also corrode in the presence of solvent degradation products.

Lower cost CS materials are unsuitable because of lower corrosion resistance when

compared with SS grades.

Way forward

Develop cheaper materials and/or metal coatings (e.g., Concrete)

Utilise Corrosion inhibitors (can reduce solvent performance)

Develop environmentally friendly, non-corrosive solvents


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Environmental Challenges

Sources of Emissions from PCC Plant

Solvent/Degradation products carry-over

Solvent/Degradation products carry-over


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Environmental Challenges – Solvent Degradation

Amine Degradation Products

It is difficult to describe the degradation chemistry of amines in CO2 capture succinctly due to; Different types of degradation mechanisms involved Different grades of amines used by different PCC vendors

Computational chemistry & modelling approaches have been used to predict the most likely amine degradation products in PCC which do not necessarily exist in reality.

“Verified and publicly available PCC plant emission data is not only incomplete but, in many cases, rely on tests which are not performed under representative conditions. Most impact assessment studies have been carried out in dry atmosphere and do not address reactions that develop in the water phase, during darkness and with other radicals present (other than hydroxide) – all of which can remove degradation products. The result is an overestimation of the level of degradation product concentrations and their persistence in the atmosphere”.

Source: HSE Impact Assessment of Amine-based Solvents in CO2 Capture, ZEP report (2011)



Health Risks: Literature studies have found that;

Most amines are biodegradable and hence, have little adverse environmental impact

The highest concentrations (if emitted) would be found in liquid phase within 1 km of the emitting PCC plant

Nitrosamines and nitramines are potential carcinogens, but have short lifetimes of 1h and upto 3 days, respectively in the atmosphere.

Where these emissions occur, their concentrations range from parts per million (ppm) to parts per billion (ppb).

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1. In-Plant Degradation

In the PCC Plant, solvent degradation can occur by thermal breakdown, oxidation and reactions with acid gases (NOx and SOx). The PCC plant will be operated to minimise the formation of any degradation products during the capture process.

Thermal degradation in the presence of CO2 typically occurs due to reactions of amines with CO2 at excessive localised reboiler surface temperatures (130 to 150 oC), forming oxazolidones. To mitigate, reboiler temperatures are kept at about 120 oC.

Oxidative degradation occurs in the absorber column due to the reaction of amines with flue gas oxygen and sulphur dioxide.

Heat Stable Salts (HSS) are also produced from the reaction of amines with acid gases (NOx and SOx). Absorber inlet NOx and SOx concentrations are typically controlled to less

than 100 ppm and 10 to 20 ppm respectively.


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2. In-Plume Degradation

Amine emissions in the off-gas can degrade further in the plume if the concentration of contaminants, particularly NOx, are high, to produce amides, nitrosamines and nitramines. However, NOx concentration in the plume will be low due to the low NOx requirements at the inlet of the PCC plant.

3. Environmental Degradation

Amines undergo atmospheric degradation through absorption, adsorption, & photolysis processes. Generally, environmental degradation of amines is initiated by reaction with OH - radicals and, in sunlight, by photolysis.


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Environmental Challenges – Control Measures

Current Control Measures

Gas borne emissions from the PCC absorber are controlled through dissolution in water wash section(s) installed at the absorber off-gas exit.

Droplets of amine solution, which also contain degradation products in suspension and solution, could be entrained in the absorber off-gas stream and potentially escape to the atmosphere. Absorber/water wash column demisters are typically designed to minimise such entrainment.

Degradation products in the solvent solution are typically controlled to a total concentration of 2% w/w through solvent reclamation methods (thermal, Ion exchange etc).


Outline

Introduction







Concluding remarks

Q&A


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Public perception - Introduction

Source: Carbon capture & Storage association

Positive public perception is critical to the success of CCS

- Direct impact on specific projects

- Influence on Government CCS policy

- Public acceptance can be difficult to win and easy to lose

Academic studies have shown low levels of public knowledge of CCS, including in UK

- How the public learns of CCS is key to what they think of it

- Some evidence that greater public familiarity with CCS can correlate with greater public concern


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Public perception of CCS

Source: Carbon capture & Storage association

Building public understanding, awareness and acceptance is key to CCS deployment.


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Other Challenges – Financial & Legislation

FINANCIAL Current Issues

- How much is CCS going to cost?- How much energy will CCS require?

CCS Government funding/subsidy insufficient/lack of clarity

- Impact of Recession ?

LEGISLATION Lack of adequate legal & regulatory framework Lack of commitment from major polluters (US, Canada, Brazil, Russia, India, China etc.)

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Concluding Remarks – The Way Forward

The time is right for the full-scale demonstration of PCC technology

Considerable progress has been made in the development of PCC technology

-The process is technically viable

-The process is reasonably well understood

-The process has been demonstrated at pilot-scale

-The process is being demonstrated at large-scale (100+ t/day)

-Most of the individual components are in commercial operation at the required scale

PCC technology is economically competitive with alternative carbon capture technologies


In Summary

As such it is focussed on, and driving towards CCS commercialisation

Underpinning its existing technology offering

Improving the technology offering through capital and operational cost reduction

Working closely with utilities and environmental agencies to develop measurement and control standards to bolster confidence in post-combustion capture

Doosan is a forward looking, technology driven organisation, positioned to take advantage of future markets

Low impact high efficiency integrated EPC carbon capture solutions


Contact Details

Dr Saravanan Swaminathan

Senior Engineer, Product Development

E [email protected]

Mark Bryant

Director Carbon Capture

E [email protected]

Matthew Hunt

Business Development Manager

E [email protected]

Indian Office Contact details to be added?

Doosan Power Systems Limited Porterfield Road Renfrew PA4 8DJ United Kingdom

T +44 (0)141 886 4141

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Thank youDisclaimer:The contents in this presentation are for information purposes only and are not intended to be used or relied upon by the reader and are provided on the condition that you 'use it at your own risk'. Doosan Power Systems Limited does not accept any responsibility for any consequences of the use of such information.

All rights are reserved and you may not disseminate, quote or copy this presentation—written by Doosan Power Systems Limited—without its written consent.

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