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CCS Project with Alstom's Chilled Ammonia Process at AEP's

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CCS Project with Alstom's Chilled Ammonia Process at AEP's CCS Project with Alstom’s Chilled Ammonia Process at AEP’s Mountaineer Plant Paper No. 72 Rob Bollinger David Muraskin Project Manager Alstom Power, Inc. American Electric Power CAP Technology Manager 1 Riverside Plaza Environmental Control Systems Columbus, OH 43215 1409 Centerpoint Blvd USA Knoxville, TN 37932 Tel: +1 614 716 3766 USA E-Mail: [email protected] Tel: +1 865 694 5269 E-Mail: [email protected] Mike Hammond Fred Kozak Project Engineer Alstom Power, Inc. American Electric Power CAP Technology Development 1 Riverside Plaza Environmental Control Systems Columbus, OH 43215 1409 Centerpoint Blvd USA Knoxville, TN 37932 Tel: +1 614 716 5931 USA E-Mail: [email protected] Tel: +1 865 560-1373 E-Mail: [email protected] Gary Spitznogle Matt Cage CO2 Storage Technical Lead Alstom Power, Inc. American Electric Power Project Engineer 1 Riverside Plaza Environmental Control Systems Columbus, OH 43215 1409 Centerpoint Blvd USA Knoxville, TN 37932 Tel: +1 614 716 3671 USA E-Mail: [email protected] Tel: +1 865 694 5888 E-Mail: [email protected] Brian Sherrick Michael Varner Project Manager Alstom Power, Inc. American Electric Power Project Manager 1 Riverside Plaza Environmental Control Systems Columbus, OH 43215 1409 Centerpoint Blvd USA Knoxville, TN 37932 Tel: +1 614 716 1923 USA E-Mail: [email protected] Tel: +1 865 694 5897 E-Mail: [email protected] ©ALSTOM Power Systems 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Page 1 / 19 ABSTRACT Alstom and American Electric Power have jointly participated in the design, installation, start-up, and operation of a carbon capture and storage (CCS) project using Alstom’s Chilled Ammonia Process (CAP) at AEP’s Mountaineer Power Plant. AEP has engaged Battelle to develop a geologic storage system to store the CO2 in porous rock formations located at the power generation facility site. The CCS project “Product Validation Facility (PVF)” at Mountaineer is approximately 20 megawatt electric (MWe) in size and involves the treatment of a slipstream of combustion flue gases from an existing coal-fired boiler. Initial operation of the Product Validation Facility occurred in September 2009 with initial storage of CO2 into a geologic storage formation in October 2009. Alstom’s experiences obtained at other CAP pilot plants have been used to support the Mountaineer PVF and are summarized in the paper. INTRODUCTION The development of CO2 capture technologies is being pursued by US, European, and other global suppliers in collaboration with utility companies, academia and universities as well as Governments particularly in the US (Department of Energy), Europe, Canada and Australia. Several post-combustion solutions are currently being developed. Among the most interesting is Alstom’s Chilled Ammonia Process, which continues to be tested on several pilot and validation facilities. The following paper will first describe the Chilled Ammonia Process and provide an update on the progress made at two of Alstom’s pilot plant facilities, the We Energies and E.ON Karlshamn Field Pilots. In addition, the paper will describe the design, and summarize the development and initial operation of the AEP Mountaineer CO2 Capture Product Validation Facility and Geologic Storage Project. The Field Pilot at We Energies, sized to capture over 15,000 metric tons/year of CO2 at full capacity, commenced operations in June 2008. Tests ended in October 2009 and the gathered operating experience has resulted in a greatly improved understanding of the process and the interactions with the power plant. The Field Pilot at the E.ON Karlshamn location was commissioned in April 2009 and captures CO2 emissions from a boiler combusting a high sulfur fuel oil. The “Product Validation Facility” (PVF) at American Electric Power’s (AEP) Mountaineer (MTN) plant is designed to treat a 20 MWe slipstream of combustion flue gases from an existing coal-fired boiler. The flue gas is taken downstream of the plant’s existing selective catalytic reduction (SCR), particulate control, and wet flue gas desulfurization (WFGD) systems. The project scope includes CO2 capture, compression, and storage in two geologic reservoirs with injection wellheads located on the plant property. AEP has been working with Battelle to develop the geologic storage system. This unit was inaugurated in September 2009 and is capable of capturing and storing 100,000 metric tons per year of CO2. This unit represents a major step in the technology scale-up process. The Electric Power Research Institute (EPRI) will provide support to obtain measurements and assess the performance of the facility. ©ALSTOM Power Systems 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Page 2 / 19 DESCRIPTION OF THE CHILLED AMMONIA PROCESS The configuration of CAP at each of the three locations where it has been deployed is very similar. Since this paper is intended to focus on the Product Validation Facility at AEP Mountaineer, the process description presented in this section will be based on that facility. Process Chemistry The Chilled Ammonia Process is based on the chemistry of the NH3-CO2-H2O system and the ability of ammoniated solution to absorb CO2 at low temperature and to release the CO2 at moderately elevated temperature. The primary CAP chemical reactions for CO2 capture are presented in Equations 1–4. During absorption, CO2, ammonia, and water combine to form ammonium carbonate, ammonium bicarbonate and ammonium carbamate mainly in ionic forms. CO2 (g) Í==Î CO2 (aq) (1) 2NH3 (aq) + H2O (l) + CO2 (aq) Í==Î (NH4)2CO3 (aq) (2) (NH4)2CO3 (aq) + CO2 (aq) + H2O (l) Í==Î 2(NH4)HCO3 (aq) (3) (NH4)2CO3 (aq) Í===Î (NH4)NH2CO2 (aq) + H2O (l) (4) The reactions in the process are all reversible and their direction depends on pressure, temperature and concentration in the system. Equations 1-4 are exothermic reactions in the left to right direction requiring removal of heat from the process in order to maintain the desired CO2 absorption temperature. Equations 1-4 are endothermic reactions in the right to left direction that require energy to produce the desired products. Ammonium bicarbonate is the least soluble salt in the system and depending on process conditions, primarily concentration and temperature, ammonium bicarbonate may precipitate as crystalline salt, as shown in equation 5. (NH4)HCO3 (aq) Í===Î (NH4)HCO3 (s) (5) Overall chemical reactions associated with removal of residual SO2 in the flue gas in the cleaning and cooling stage of the CAP process are provided below in Equations 6 and 7. SO2(g) + 2NH3(g) + H2O(aq) ⇒ (NH4)2SO3(aq) (6) (NH4)2SO3(aq)+ 1/2O2(g) ⇒ (NH4)2SO4(aq) (7) ©ALSTOM Power Systems 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Page 3 / 19 CAP Unit Operations As configured for the Mountaineer PVF, the Chilled Ammonia Process (CAP) consists of the following unit operations: • Flue gas conditioning and ammonia capture • Absorbers for CO2 capture • NH3 water wash column for ammonia capture • Regenerator for CO2 release and reagent replenishment • Stripper for ammonia recovery and wash water conditioning • CO2 dehydration and compression • Refrigeration system • Reagent storage & feed The overall unit is configured as shown in Figure 1: Figure 1 – Chilled ammonia process flow diagram Flue Gas Conditioning A portion of the flue gas from the outlet of the upstream WFGD is directed to the Chilled Ammonia Process for treatment. The flue gas stream contains between 10 and 13% CO2 depending on the power output and operation of the plant. The flue gas operating temperature is approximately 125 to 135°F (52 to 57°C) and is saturated with respect to moisture. Also present are residual contaminants such as SO2, SO3, HCl, and particulate matter (PM). ©ALSTOM Power Systems 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Page 4 / 19 The Flue Gas Conditioning system consists of two packed bed sections, Direct Contact Cooler 1 (DCC1) and Direct Contact Cooler 2 (DCC2), and a circulation loop through an evaporative cooling tower. The flue gas is cooled in DCC1 to condense and remove moisture from the flue gas. The solution pH in the DCC1/DCC2 loop is controlled to facilitate high SO2 capture efficiency in the DCC1 and high NH3 capture efficiency in DCC2. The use of the incoming SO2 and acid gases is effective in the removal of ammonia leaving the CAP as one (1) mole of SO2 captured in DCC1 reacts with two (2) moles of NH3 captured in DCC2 to produce ammonium sulphate product. In the AEP Mountaineer PVF the upstream WFGD operates at very high SO2 capture efficiency with low residual SOx in the flue gas. As such, sulfuric acid is added in the DCC2 to capture residual ammonia in the flue gas prior to exiting the Chilled Ammonia Process. The DCC2 design is an efficient ammonia removal device that results in high capture efficiencies and low ammonia emissions at the AEP Mountaineer PVF.
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