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Industrial Implementation of Carbon Capture in Nordic Industry Sectors

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Industrial Implementation of Carbon Capture in Nordic Industry Sectors IndustrialimplementationofCarbon CaptureinNordicindustrysectors KristinOnarheim,StefanìaÒ.Garðarsdòttir, AnetteMathisen,LarsO.Nord,DavidBerstad(eds.) NORDICCSTechnicalReportD4.2.1501/D18 November2015 Summary This report investigates the feasibility of separating CO2 from industrial gas streams for carbon capture and storage (CCS) in the Nordic countries. Detailed case studies were developed for iron and steel production, cement production, pulp and paper production, oil and gas refineries, and geothermal power production. Available technologies for separating CO2 have been reviewed and detailed process simulations on the technologies feasible for implementation for the specific cases have been performed. The work shows it is feasible to apply carbon capture technologies to a broad set of process conditions. However, it is crucial to consider the specific conditions of each case as they strongly affect the performance of the technologies and the choice of technology. Considering process and site specific conditions as well as possible developments of the industrial process simplifies the implementation and increases the efficiency of carbon capture considerably. The specific findings for each case study are summarized below. Iron and steel production The steel mill case study showed that replacing the conventional gas powered steam cycle in the power plant with a low-BTU gas turbine improves process performance. Adding a water-gas shift reactor and a CO2 capture process further increases the top gas fuel value. An additional 70 MW electric output can be achieved from this process configuration with a CO2 reduction of about 80% - 85%. Furthermore, the design allows for a staged deployment of the concept, which minimizes the investment risk and burden of implementation. Cement production The case study on cement production favored a retrofit of the existing process by implementing an amine-based CO2 capture plant. The capture unit can be added without any major updates of the cement plant. The most important installations required are the exhaust gas waste heat recovery unit, which will cover part of the steam needed to separate the CO2, and the installation of exhaust gas cleaning equipment for SOX, NOX, and dust before the capture unit. Oxy-fuel combustion is also a feasible option for the cement case. In general, few modifications of the cement plant are required to implement oxy-fuel technology. To avoid air in-leakages in the cement plant, which has a considerable influence on the energy consumption of the compression and CO2 purification unit, is one of the largest concerns for a retro fit of oxy-fuel combustion. Pulp and paper production The pulp production case considers possibilities with bio-energy with CCS (BECCS) as pulp mills mainly have biogenic CO2 emissions. This work investigated the possibilities of implementing carbon capture to pulp mills using a conventional recovery boiler or black liquor gasification (BLG) technology. The latter scenario using either the Selexol process together with a combined cycle for electricity production or the Rectisol process together with dimethyel ether (DME) biofuel production proved a high performance. The results show that the pulp and paper industry is suitable for BECCS. The combination of BLG technology and CO2 capture would require low additional utility, compared with the conventional post-combustion process. Oil and gas refineries The case study on a refinery highlights the complexity of the refinery process that gives a large variety in size and quality of the many CO2 sources. It is therefore of importance to investigate the sub-processes of the refinery individually. The most favorable CO2 sources is the steam-methane reformer for hydrogen production due to high CO2 content in the flue gas and being the largest point source of CO2. The refinery also includes CO2 sources that are not suitable for CO2 capture, mainly due to their relatively small size, which will have the consequence that the overall capture efficiency of the refinery will be below the 85-90% that is possible to achieve on an individual stream. Geothermal power production The case study on geothermal power in Iceland is a unique example of a CO2 source that is highly suitable for capture. The plant is already required to recover the high amounts of H2S in the gas and there are several technology options for removing the H2S and CO2 from the turbine off-gas. Absorption in water as well as in amines was investigated with promising results. Also cryogenic gas separation would be technically feasible. Furthermore the results show the possibility of achieving a pure hydrogen stream if an extra pressure swing adsorption (PSA) unit is added. Keywords CCS implementation, Nordic industry, CO2 emissions Editors Kristin Onarheim, VTT Technical Research Centre of Finland, Ltd., Finland [email protected] Stefanìa Òsk Garðarsdòttir, Chalmers University of Technology, Sweden [email protected] Anette Mathisen, Tel-Tek, Norway [email protected] Lars O. Nord, NTNU, Norway [email protected] David Berstad, Sintef Energy Research, Norway [email protected] Authors Kristin Onarheim (VTT Technical Research Centre of Finland, Ltd., Finland), Stefanìa Òsk Garðarsdòttir (Chalmers University of Technology, Sweden), Anette Mathisen (Tel- Tek, Norway), Lars O. Nord (NTNU, Norway), David Berstad (Sintef Energy Research, Norway), Fredrik Normann (Chalmers University of Technology, Sweden), Klas Andersson (Chalmers University of Technology, Sweden), Filip Johnsson (Chalmers University of Technology, Sweden), Joakim Hedström (Chalmers University of Technology, Sweden), Antti Arasto (VTT Technical Research Center of Finland, Ltd., Finland), Maria M. Skinnemoen (NTNU, Norway) Date November 2015 About NORDICCS Nordic CCS Competence Centre, NORDICCS, is a networking platform for increased CCS deployment in the Nordic countries. NORDICCS has 10 research partners and six industry partners, is led by SINTEF Energy Research, and is supported by Nordic Innovation through the Top-level Research Initiative. The views presented in this report solely represent those of the authors and do not necessarily reflect those of other members in the NORDICCS consortia, NORDEN, The Top Level Research Initiative or Nordic Innovation. For more information regarding NORDICCS and available reports, please visit http://www.sintef.no/NORDICCS. Contents SUMMARY......................................................................................................................................2 INTRODUCTION...........................................................................................................................8 Nordic industrial CO2 emissions........................................................................................................................ 8 Aim of research .............................................................................................................................................. 10 METHODOLOGY.........................................................................................................................11 CO2 capture technology .................................................................................................................................. 11 Energy supply and integration of CO2 capture ................................................................................................ 15 CARBONCAPTUREINIRONANDSTEELPRODUCTION...................................................16 Process overview ........................................................................................................................................... 16 CO2 capture in iron and steel production........................................................................................................ 17 Case study – Modified blast furnace and power production processes .......................................................... 18 Conclusions .................................................................................................................................................... 25 References ..................................................................................................................................................... 27 CARBONCAPTUREINCEMENTPRODUCTION...................................................................29 Process overview ........................................................................................................................................... 29 CO2 capture in cement production ................................................................................................................. 29 Case study A – Retrofit application of carbon capture .................................................................................... 30 Case study B – Oxy-combustion ..................................................................................................................... 33 Conclusions .................................................................................................................................................... 35 References ..................................................................................................................................................... 37 CARBONCAPTUREINPULPANDPAPERPRODUCTION..................................................38 Process overview ..........................................................................................................................................
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