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CSIRO PCC Pilot Plant Activities in Australia

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CSIRO PCC Pilot Plant Activities in Australia CSIRO PCC Pilot Plant Activities in Australia Aaron Cottrell 19th May 2011 – Abu Dhabi, United Arab Emirates 1st Post Combustion Capture Conference The role of coal in Australia Australia is heavily dependant on coal for electricity production Large reserves of coal will likely mean future power stations will be coal based Electricity production ~ 261TWh CO2 emissions from electricity production ~ 235 Mt CO2 Other Other NG NG Brown Coal Black Coal Black Coal Brown Coal Abare data : 2008-2009 PCC application in Australian coal fired power stations Generation capacity ~ 28 GW Electricity production 201 TWh Average generation efficiency • Black coal: 35.6% - 0.9 tonne CO2/MWh • Brown coal: 25.7% - 1.3 tonne CO2/MWh CO2-emissions ~ 202 Mtonne CO2/a from ~ 60 flue gas streams SO2 levels: • Black coal: 200 - 600 ppm No FGD • Brown coal: 100 - 300 ppm NOx levels: • Black coal: 300-700 ppm No DeNOx • Brown coal: 100-200 ppm +90% NO Flue gas temperature • Black coal: 120 oC High flue gas temps • Brown coal: 180 oC Cooling water: 1.5-3.0 m3/MWh Data used from CCSD – technology assessment report 62 Opportunities for PCC in Australia Only practical option for existing plants to substantially reduce CO2 intensity Potential for “all in one” multi pollutant control technology Compared to competing technologies, has high flexibility & adaptability • staged implementation, zero to full capture operation to match market conditions • applicable to most stationary sources of CO2 emissions Special synergies with renewable energy • direct solar integration (provision of low temperature heat for solvent regeneration avoids reducing output of power station) • grid integration (provides a discretionary load to balance intermittency) Potential water production source Potential waste heat recovery options Integrated PCC R&D Programme 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) PCC Programme Overview PCC Learning by doing Learning by searching Pilot plants Research & Development Novel solvents Loy Yang Power CET Ionic liquids CET Adsorbents E&M Delta Electricity Enzymes Solvent synthesis ENT CMHT China Huaneng Novel processes Environmental impacts CET CET Tarong Energy Economics & Integration CET Pilot plant summary Plant Loy Yang Munmorah Tarong Newcastle mini Solvent Amine Ammonia Amine Both Flue gas brown coal black coal Black coal Artificial source Scale 50 kg/hr 300kg/hr 100kg/hr 20 kg/hr Focus solvent ammonia process process benchmarking operation optimisation development Other emission pressurised Solar thermal Cutting edge activities study absorption integration processes • Pilot work by nature is slow to deliver results • Matrix approach helps cover many aspects of PCC as well as providing quicker delivery of information • Multiple plants provide extra exposure for power generators Key gas analysis equipment Each pilot plant has sophisticated FTIR gas analysis equipment (Gasmet). Enables online sampling of up to 8 different location on the plant Currently includes spectra for calculating online concentration of CO2, H2O, CO, NO2, NO, N2O, SO2, HCl, HF, NH3, MEA, PZ and a number of breakdown products Overall spectra are saved and can be analysed for other “unknown” constituents at a later date. Highly valuable for measuring plant performance, safety and water balancing Loy Yang Power Station PCC Pilot Plant Victoria, Australia ETIS support Lignite Amine based No FGD/DeNox Operational May 08 Project aims • Develop experience operating PCC on brown coal flue gas • Strong focus on solvent testing and benchmarking • 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 Loy Yang Pilot Plant design Basis of Design: Two absorbers with CO2 capacity up to 50 kg/hr Each has 2 beds of 1.35 m packed with 5/8” Pall rings – 338 m2/m3, ID 211 mm Stripper: 3.9 m bed with Pall rings, ID 161 mm Flue gas composition (11% CO2, 30% H2O) MEA concentration (30%) Operation Conditions: Reboiler temperatures: 100 – 120 °C Stripper pressures: 1 - 2 bar Flue gas temperatures: < 180 °C Objectives: determine Mass & Heat balances for the plant determine CO2 recovery and CO2-product quality determine thermal and electrical energy requirements of the pilot plant Some results from the Loy Yang pilot plant Liquid analysis CO2 product based treated flue gas based 100 • First CO2 capture in May 2008 90 • Able to successfully close 80 recovery (%) mass balances over the plant. 2 70 CO Agreement between different 60 methods for determining plant 50 CO2 recovery 1.5 2.0 2.5 3.0 3.5 4.0 4.5 L/G (L/Nm³) Effect of L/G ratio of CO2 recovery • Effect of various operating 6.0 (69%) ) conditions of plant 2 (60%) (72%) 5.5 performance observed (e.g. (90%) (75%) (83%) effect of L/G ratio on CO (89%) 2 5.0 (81%) recovery and reboiler duty (84%) (83%) 4.5 Reboiler heat duty (MJ/kg CO (MJ/kg duty heat Reboiler Artanto et. al. 2009 4.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 Effect of L/G ratio of Reboiler duty L/G (L/Nm³) Conclusions/Remarks on Solvent bench-marking • MEA has been used as a base case - minimum in pilot: 4.3 MJ/kgCO2 • MEA + AMP and AMP + PZ were used as amine blends and showed decreased heat duty of 10-30%. Kinetics dropped considerably though; • The RITE solvent, a proprietary amine blend, shows a 20-34% decrease of the heat duty and combines that with seemingly good kinetics; • Design choices such as packing height, based on MEA properties, has affected the optimal performance of slower reacting, low energy consuming solvents. The brown-coal case demands low investment costs, hence high reactive solvents; • Operational issues such as viscosity limits and potential corrosion have limited the impact of results. Key learnings from LVPCC project 1. Due to the relatively cheap brown coal supply, cost reductions can be achieved by a focus on reduction of the capital costs and to a lesser extent on the reduction of the energy penalty. • Solvents with better kinetics • Solvents with lower vapour pressures • Thermally stable solvents • Cheaper materials for plant construction • Simple process design 2. Requirement of FGD and DeNOx may mean PCC for brown coal not feasible. “All in one” technology may have merit. • Once again capital driven • Less efficient solvent capable of multi pollutant control may be key • Maybe by-products give value Ongoing Research • Original ETIS project has been completed • Ongoing solvent testing and benchmarking • Detailed investigation of PCC emissions - quantify environmental impact of PCC - determine any associated control technologies are required • Collaboration with an EU consortium in the iCap project. - CSIRO will form part of an Australian consortium called coCAPco working with iCap - aim to develop and test a combined CO2 and SO2 capture process with stepwise regeneration. Munmorah Power Station PCC Pilot Plant New South Wales, Australia APP support Black coal Aqueous ammonia based No FGD/DeNox Operational Feb 09 Why ammonia for PCC? •Ammonia is a relatively cheap liquid absorbent. •Ammonia is robust and not subject to degradation unlike other amines. •Multi pollutant control – lower capital costs •Potential for reduced energy consumption in solvent regeneration •Potential for more efficient compression via high pressure regeneration pressure •Potential income stream from ammonium sulfate and ammonium nitrate by-products Munmorah Pilot Plant design Basis of Design: Two absorbers with CO2 capacity up to 150 kg/hr Each has 2 beds of 1-2 m packed with 1” Pall rings – 207 m2/m3, ID 600 mm Stripper: 3.5 m bed with Pall rings, ID 400 mm Flue gas composition (11% CO2, 30% H2O) MEA concentration (30%) Operation Conditions: Reboiler temperatures: 100 – 180 °C Stripper pressures: 1 - 10 bar Flue gas temperatures: < 120 °C Objectives: determine Mass & Heat balances for the plant determine CO2 recovery and CO2-product quality determine thermal and electrical energy requirements of the pilot plant Finding the right balance Smaller absorber (low capital cost), high Large absorber (high capital cost), lower operating cost and high solvent loss operating cost and lower solvent loss Some results Ammonia losses in absorber Precipitation of solids in condenser Measured and equilibrium ammonia concentrations in the flue gas at the outlet of absorber as a function of CO2 loading of lean solvent. Expt: 15-20oC; Model: 15oC. Key Outcomes of the Munmorah Pilot Plant Benefits of aqueous ammonia process are confirmed ……. but further challenges also revealed: • The ammonia losses, as a result of its high volatility, can be substantial (depending on the operating conditions) necessitates the installation of a comprehensive gas washing and ammonia recovery/neutralisation system. operation at low temperature – refrigeration is expensive to buy and run • The CO2 absorption rates are low larger absorbers compared to the standard amine processes. effect on investment costs? • Matching operation to
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