11th MEETING
of the
INTERNATIONAL POST-COMBUSTION CO2
CAPTURE NETWORK
Post Combustion Systems
Coal Fired Pilot Plant and Multipollutant Control
Masaki Iijima
20th -21st May, 2008 Vienna, Austria
CONTENTS
1. MHI’s Commercial Achievements
2 MHI’s Long Term 10 t/d CO2 Capt
2.
Capture
re
Demonstration Tests from a Coal Fired Boiler
3 MHI’s CO2 Recovery
3.
Reco er Technolog
Technology: Process
Improvements & Heat Integration
4 Ph
4.
Phased
d Approach
A
h to
t Commercialization
C
i li ti for
f
Coal Application
5 MHI’s
5.
MHI’ S
Scope iin a CCS Project
P j t
6. Conclusions
1. MHI’s Commercial Achievements
MHI’s Operating Commercial CO2 Capture Plants
Malaysia
India
Client: Petoronas
Start up: 1999~
Start-up:
CO2 Source:
Nat. Gas Reformer
Capacity: 200 t/d
Product: Urea
Client: IFFCO
Location: Aonla
Start-up: Dec 2006~
CO2 Source:
Nat. Gas Reformer
Capacity: 450 t/d
Product: Urea
Japan
India
Client: Chemical Co.
Start-up:
Start
up: 2005~
2005
CO2 Source:
Nat. Gas Boiler
Capacity: 330 t/d
Product: General use
Client: IFFCO
Location: Phulpur
Start-up: Dec 2006~
CO2 Source:
Nat. Gas Reformer
Capacity: 450 t/d
Product: Urea
1. MHI’s Commercial Achievements
MHI’s
MHI
s Recently Awarded Commercial Projects
OTHER
PROJECTS
Abu
Dhabi
India
Bahrain
‘Asia’
Asia
China
Project Status
Under
Construction
Under
Construction
Under
Construction
Under
Construction
FEED
Complete
Flue Gas
Source
Nat. Gas.
Reformer
Nat. Gas.
Reformer
Nat. Gas.
Reformer
Nat. Gas.
Reformer
Nat. Gas.
Boiler
Expected on
stream
2009
2009
2010
2010
TBC
CO2 Capture
Capacity (T/D)
400
450
450
340
800
2. MHI’s long term 10 t/d CO2 capture demonstration tests from a coal fired boiler
Coal Fired Long Term Demonstration Plant
Plant Outline
Solvent :
C
Capacity
it :
Feed Gas :
Start-up :
Location :
KS-1
10 T/D
Coal Fired Boiler (14.1 v% CO2)
July 2006
Nagasaki,
g
, Japan
p
Operational experiences
‡ Increased understanding of the effects of impurities
on the system (dust, SOx, NOx, etc.)
‡ Identifying and incorporating countermeasures for
each impurity
‡ >5,000 hours of operation and experience
‡ Test results exceeded expectations and will
facilitate scale up CO2 capture for coal fired boilers
‡ Confirms that the MHI CO2 capture process can
be applied to coal fired flue gas streams
2. MHI’s long term 10 t/d CO2 capture demonstration tests from a coal fired boiler
Coal Fired Long Term Demonstration Plant - Results
Test Item
Result
• Achieve long term stable operation
9 >5000 hours of near continuous operation
• Confirm effect of various impurities on CO2
capture process & equipment
9 Advanced know-how of the impacts of dust, SO2
and NOx
• Achieve high CO2 purity performance
9 >99.9% achieved
• Confirm heat consumption required for CO2
recovery
9 730-820 kcal/kg-CO2
(Improved process reduced by a further 15%)
• Record pressure loss observed in the cooler and
absorber
9 No major pressure fluctuations
• Confirm process can be applied to coal fired flue
gas
9 Yes - KM-CDR Process can be applied to coal
fired power stations
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
Process Flow for Amine Absorption
p
Boiler
Particulate
Capture
Facility
DeNOx
FGD
Stack
Flue Gas
Outlet
CO2 Purity 99.9 %
Flue
Gas
Treated Flue Gas
CO2
Capture
Compression
&
Dehydration
CO2
Product
ABSORBER
STRIPPER
(Regenerator)
C.W.
Flue Gas
Fl
G
Cooler/Deep FGD
C.W.
Flue Gas
Pre-treated Flue gas
C.W.
Steam
Reboiler
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
MHI’s Flue Gas CO2 Recovery
y Improved
p
Process
Recovered CO2
„ 15% steam consumption reduction over
MHI’s conventional p
process
„ Advanced process demonstrated at MHI’s
Nanko Pilot Plant & Commercial Plants
„ Process Features
Utilize lean solvent and steam condensate
heat for regeneration inside the stripper
Heat Recovery
&
Solvent
Regeneration
Stripper
CO2
Steam
Lean solvent
„ Performance
Steam Condensate
*Steam Consumption: 1.30 Ton Steam/ Ton
CO2 (660 Kcal/ Kg CO2)
Advanced Amine Solvent ‘KS-1’
Note: Steam = 3 BarG Saturated
• High CO2 Loading
*Regeneration Energy less than 700 Kcal/ Kg CO2 can
be guaranteed
Patent Application submitted in various countries
• Low Solvent Degradation
• Low
L
C
Corrosion
i
• No Corrosion Inhibitor
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
MHI Heat integration
g
Concept（Base
p（
Case))
①
②
LP Steam extraction from the LP Turbine
Recovery of overhead condenser heat
LP Turbine
HP/MP
Turbine
Air Heater ESP
Boiler
①
②
Reboiler
Condenser
Regenerator
Condenser
Deaerator
Boiler Feed Water Pump
JP Patent No. 207444
Boiler Feed Water Pump
Boiler Feed Water Heater
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
MHI Heat integration
g
Concept
p
MP Turbine
900
C
HP Turbine
800
A
D
G
700
Enthalpy
(kcal/kg)
Extraction to Reboiler
B
LP Turbine
600
E
E
Steam Condensing
Curve
500
200
Reboiler
Condensate
Power loss of
steam turbine
Utilize this heat for
the reboiler
Waste Heat from
the condenser
H
100
F Condensate
0
Entropy (kcal/kg･K)
Utilize waste heat of CO2 recovery
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
CO2 Recovery Plant Power Output Penalty Assessment and Heat Integration Options;
1) Base Case +
2) Recovery of Compression Heat
3) Recovery of Flue Gas Heat
Power output penalty of CO2 capture and
compression without heat integration
CO2 Compressor
Power Output (M
MW)
1 000
1,
800
600
400
1200
Deep FGD
CO2
Recovery
Auxillary
Equipment
Power Loss by LP
Steam Extraction
Power Output Penalty
by MHI CCCP
(Base Case)
22% of Gross Output
Power Output
Penalty
decreased to
20%
1000
800
Net Output
+
Plant Auxiliary
Equipment
Power
Consumption
200
Power Output (M
MW)
1,200
Net output improvement with heat
integration
Power Output
Penalty by MHI
CCCP
600
Net Output
+ Plant Auxiliary
Equipment Power
400
CCCP:
CO2 Capture,
Compression Plant
200
0
0
1,070MW (Gross) Supercritical Pulverized
Coal Power Plant; Bituminus Coal Case
Without CCCP
With MHI
CCCP (Base
Case)
With MHI
CCCP + Max
Heat
Integration
3. MHI’s CO2 Recovery Technology: Process Improvements & Heat Integration
Multi Pollutant Test Plant (FGD & CO2 Capture)
Multi-Pollutant
Absorber 1 by 1 Scale Test Facility (400 MW equivalent)
Absorber
Spray pipes
Fan
32 m
Recirculation Pumps
Commercial Scale Tests
• Q1 2008 – Extensive
E t
i
Liquid Distribution Tests
• Rectangular Absorber
• Panel Design
4. Phased approach to commercialization for Coal application
MHI’s Operating Experience
• Pilot plants (1-2 t/d)
• Small scale demonstration plant (10 t/d)
• Commercial plants (200-450 t/d)
• Experience with natural gas and coal
2 t/d
10 t/d
Pilot scale experience
(Natural Gas & Coal)
200 t/d 330 t/d
450 t/d
Commercial Experience
(Natural Gas)
800 t/d
～500 t/d
FEED Complete
(Natural Gas)
Phase 1
(Coal)
Fulll scale com
mmercial
Med
dium scale demo
1 t/d
3000 t/d ～3000 t/d
Basic Design
Complete (Nat. Gas)
Phase 2
(Coal)
4. Phased approach to commercialization for Coal application
MHI s Conceptual Schedule for a Medium – Large
MHI’s
Scale Coal Fired CO2 Capture Demonstration Plant
Y
Year
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
Pilot Test (1 t/d)
MHI Funded Coal Fired CO2
p
Testing
g
Capture
Small Scale Demo (10 t/d)
Small Demo Operation
Completed
p
-2p
phases
Medium Scale Demo (500 t/d)
Demo Plant Starts
Commercial Deployment (>3000 t/d)
Commercial Plant Starts
FEED
Project
Organization
Construction
Operation
Note: This schedule is a conceptual figure only and shows MHI’s roadmap for the future commercialization of this technology for coal fired boilers
18
5. MHI’s Scope in a CCS Project
Steam Turbine
Boiler
SCR
NOx
EP
Dust
FGD
CO2
Capture
SOx
CO2
CO2
Transport
CO2
Compression
‹Centrifugal Compressors
‹Coal Fired Power Station
‹FGD
‹CO2 Capture Plant
ABSORBER
COOLER
STRIPPER
DCFS
MHI Can Supply All Technology – Efficient Integration
6. Conclusions
Need for Carbon Capture & Storage
①
Coal will remain a dominant fuel for electric power generation
②
Coal with CCS technology can play an important part in CO2
mitigation - regulatory certainty and political support is needed
③
Governments must continue to support CCS and a ‘suite’ of
carbon mitigation strategies
④
Incentives for first stage commercial CCS plants are necessary
to reduce technical and financial uncertainties
⑤
Post combustion CO2 capture technology offers many
advantages and can be transferred to developing countries
⑥
Allows for future zero emission use of coal