Pilot study on the CO2 removal from flue gas in an amine-based plant at Tauron’s Power Plants
Adam Tatarczuk, Institute for Chemical Processing of Coal, Poland
8th International
Scientific Conference
on Energy and
Climate Change
9th October 2015
35.6%
21.0%
6.6% 1.5%
15.7%
18.8%
0.5% 0.3%
Year 2030 – 201,8 TWh
44.90%
36.47%
3.57%
1.78%
0.00%
12.13%
0.71% 0.43%
Year 2015 – 140,1 TWh hard coal
lignite
natural gas
oil products
nuclear
renewables
water
others
Fuel mix in power generation - Poland
* „Energy Policy of Poland until 2030” (Ministry of Economy2009) 2
The main technology options for CO2 capture from power plant
3
„…post-combustion carbon capture is winning.”
• Possible to implement to existing Power Plants
• High efficient coal-fired power units „50 +”
• Large demonstration projects with post- combustion CCS :
• WA Parish Petra Nova , US, start 2016 – 240 MW,
• ROAD , NL, start 2017 – 250 MW,
• Boundary Dam, Kanada, 2014 – 150 MW,
* John Gale - IEA Greenhouse Gas R&D Programme (IEAGHG) (Co-Chair) - GHGT-
12 Conference, 2014 4
Stalowa Wola Power Plant
330 MWe 465,9 MWt
Siersza Power Plant
666 MWe 36,5 MWt
Jaworzno Power Plant
1 535 MWe 369,3 MWt
Łaziska Power Plant
1 155 MWe 196 MWt
Łagisza Power Plant
850 MWe
343,4 MWt
Blachownia Power Plant
165 MWe 256 MWt
Electric Power– 4 671 MWe Thermal Power– 1 667,1 MWt
About TAURON Group – power plants
5
Institute for Chemical Processing of Coal, Zabrze, Poland
Clean Coal Technology Centre
Institute for Chemical Processing of Coal
6
Clean Coal Technology Centre, Zabrze, Poland
Pressurized gasification and oxy-combustion
in CFB reactor (50 kg/h)
Biomass gasifier (15 kg/h)
Solid fuels dryer (100 kg/h)
Coal Coking test plant
(40 kg)
Chemical looping reactor (10m3/h)
7
General information • Project name:
Development of a technology for highly efficient zero-emission coal-fired
power units integrated with CO2 capture.
• Objective:
The main purpose of the project was to demonstrate the post combustion
proces in pilot plant connected to coal-fired power plant.
• Principal:
National Research and Development Center (Poland)
• Project duration:
1.04.2010 – 30.11.2015 (67 months)
• Executors:
TAURON Polish Energy, TAURON Production,
Institute for Chemical Processing of Coal (IChPW)
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IChPW CO2 capture process scale-up strategy Lab stand for CO2 capture process – 5 m3/h (2011)
PDU for CO2 capture process – 100 m3/h (2012-IChPW Zabrze)
The Mobile Pilot Plant – 200 m3/h (2013-Tauron Power Plant)
Experimental apparatus of CO2 absorption kinetics and equilibriums in amine blends (2010)
9
Pilot plant deployment - Jaworzno Power Plant – 04.2014
10
The Pilot Plant commissioning–05.2014 Jaworzno Power Plant (TAURON)
Column diameter: 300 mm
Column height: 15,0 m
Number of devices: 40
Measurements: 180 points
Solvent: amines solution
Solvent stream: up to1800 dm3/h
Gas stream: up to 200 m3n/h
Tested gas: Flue gas from
hard–coal boiler
11
Deep desulphurization module Amine scrubbing module
The Pilot Plant simplified flow diagram
12
Split-flow Inter heating
Results and discussion Nomenclature
Parameter Description Unit
CO2 recovery Amount of CO2 captured divided by
amount of CO2 in flue gas
Typical values: 80 – 90
%
Reboiler heat duty Energy delivered to the process
divided by amount of CO2 captured (
gross values- with heat losses)
Typical values: 3 – 5
13
Results and discussion– selected campaign
Effect of heating power Effect of
desorption
pressure
L/G ratio
Effect of
absorption temp.
CO2 recovery
CO2 concentration [% vol.]
Reboiler heat duty [MJ/kgCO2]
Effect of absorption
pressure
14
90.9 93.3
96.6
3.88 4.50
5.32
0
2
4
6
8
10
12
14
16
18
20
0
20
40
60
80
100
12.17 9.94 8.14
Reb
oil
er
heat
du
ty [
MJ/k
gC
O2]
CO
2 r
ec
overy
[%
]
CO2 inlet stream concentration [% vol.]
Effect of CO2 inlet stream concentration on CO2 recovery and reboiler heat duty
Reboiler heat duty
CO2 recovery
15
Standard versus advanced configuration
16
Standard configuration Split-flow configuration Heat integrated configuration
Effect of L/G ratio on CO2 recovery and reboiler heat duty - 30 wt% MEA (different process configurations)
17
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
0
10
20
30
40
50
60
70
80
90
100
1.00 2.00 3.00 4.00 5.00 6.00 7.00
Reb
olier
heat
du
ty [
MJ/k
gC
O2]
CO
2 r
ec
ove
ry [
%]
L/G [kg/kg]
Recov. - standard conf.
Reboiler HD - standard conf.
Standard conf.
Effect of L/G ratio on CO2 recovery and reboiler heat duty - 30 wt% MEA (different process configurations)
18
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
0
10
20
30
40
50
60
70
80
90
100
1.00 2.00 3.00 4.00 5.00 6.00 7.00
Reb
olier
heat
du
ty [
MJ/k
gC
O2]
CO
2 r
ec
ove
ry [
%]
L/G [kg/kg]
Recov. - standard conf.
Recov. - heat integrated conf.
Standard conf.
Heat integrated
conf.
Effect of L/G ratio on CO2 recovery and reboiler heat duty - 30 wt% MEA (different process configurations)
19
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
0
10
20
30
40
50
60
70
80
90
100
1.00 2.00 3.00 4.00 5.00 6.00 7.00
Reb
olier
heat
du
ty [
MJ/k
gC
O2]
CO
2 r
ec
ove
ry [
%]
L/G [kg/kg]
Recov. - standard conf. Recov. - heat integrated conf. Recov. - SF + heat integrated conf.
Standard conf.
Heat integrated
conf.
Split flow + heat
integrated conf.
91.4
81.4
91.0
12.08 12.14 12.04
3.32 3.69 3.85
0
5
10
15
20
25
30
0
10
20
30
40
50
60
70
80
90
100
Re
bo
ile
r h
ea
t d
uty
[M
J/k
gC
O2]
CO
2 r
ec
ove
ry [
%]
Effect of stripper internal heating on CO2 recovery and reboiler heat duty
20
CO2 concentration Reboiler heat duty
increases 16 %
CO2 recovery
drops 10%
internal heating ON internal heating OFF
Solvent: AMP/PZ L/G: 4,0 Conf.: Split Flow
internal heating OFF + additional heat
89.3 85.4
89.6
13.68 13.68 13.71
3.61 3.74 4.03
0
5
10
15
20
25
30
0
10
20
30
40
50
60
70
80
90
100
Re
bo
ile
r h
ea
t d
uty
[M
J/k
gC
O2
]
CO
2 r
ec
ove
ry [
%]
Effect of stripper internal heating on CO2 recovery and reboiler heat duty
21
CO2 concentration Reboiler heat duty
increases 11%
CO2 recovery
drops 4 %
internal heating ON internal heating OFF
Solvent: AMP/PZ L/G: 3,2 Conf.: Multi Abs. Feed
internal heating OFF + additional heat
Results - Stripper internal heating influence matrix
Internal heat integration influence tests
Campaign Solvent L/G (kg/kg)
( Configuration)
Lean loading reduction
[molCO2/mol amine]
Heat duty reduction
[%]
J1 MEA 5,7
(Split-flow) 0,025 11,2
J5 AMP/PZ 5,7
(Split-flow) 0,050 14,0
J8 AMP/PZ 4,0
(Split-flow) 0,054 16,0
J10 AMP/PZ 3,17
(Multi absorber feed) 0,031 11,6
J13 Multicomponent 4,0 (Split-flow) 0,051 16,0
22
4.26
3.69
3.32
3.16
2.4
2.8
3.2
3.6
4.0
4.4
200 550 950 1200
Reb
oil
er
hea
t d
uty
(g
ros
s v
alu
es
) [M
J/k
gC
O2]
Pilot Plant operating hours [h]
Łaziska Power Plant - 2013 Jaworzno Power Plant - 2014
MEA 30%
Results – IChPW reboiler heat duty reduction road map (2013-2014)
23
4.26
3.69
3.32
3.16
2.4
2.8
3.2
3.6
4.0
4.4
200 550 950 1200
Reb
oil
er
hea
t d
uty
(g
ros
s v
alu
es
) [M
J/k
gC
O2]
Pilot Plant operating hours [h]
Łaziska Power Plant - 2013 Jaworzno Power Plant - 2014
AMP/PZ
MEA 30%
Results – IChPW reboiler heat duty reduction road map (2013-2014)
24
4.26
3.69
3.32
3.16
2.4
2.8
3.2
3.6
4.0
4.4
200 550 950 1200
Reb
oil
er
hea
t d
uty
(g
ros
s v
alu
es
) [M
J/k
gC
O2]
Pilot Plant operating hours [h]
Łaziska Power Plant - 2013 Jaworzno Power Plant - 2014
AMP/PZ
AMP/PZ +
Internal heaters
MEA 30%
Results – IChPW reboiler heat duty reduction road map (2013-2014)
25
4.26
3.69
3.32
3.16
2.4
2.8
3.2
3.6
4.0
4.4
200 550 950 1200
Reb
oil
er
hea
t d
uty
(g
ros
s v
alu
es
) [M
J/k
gC
O2]
Pilot Plant operating hours [h]
Łaziska Power Plant - 2013 Jaworzno Power Plant - 2014
AMP/PZ
AMP/PZ +
Internal heaters
AMP/PZ + Internal heaters +
parameters optimization
MEA 30%
Results – IChPW reboiler heat duty reduction road map (2013-2014)
26
Results - The Pilot Plant operational difficulties
• CO2 concentration fluctuations in inlet flue
gas stream
• Inlet flue gases pipeline drainage
• Additional Venturi scrubber demister due to
flue gases moisture
• Rapid corrosion
in blower
ok. 1,85 [% vol.] CO2 inlet concentration [% vol.]
Inlet flue gas stream [kg/h]
Outlet stream [kg/h]
CO2 outlet concentration [%
vol.]
27
Results - Pros and cons of the stream-splitting and internal heating
• Higher CO2 recovery • Lower reboiler heat duty • Lower OPEX due to
reduced steam demand
• Higher CAPEX due to stripper modification, additional piping and equipment (pumps)
28
Results - Simplified economic analysis
Advanced configuration
CAPEX: PLN 1000.3 M
OPEX: PLN 155.7M / year
Standard configuration
CAPEX: PLN 978.2 M
OPEX: PLN 159.7M / year
How long will it take an advanced CCS plant to pay for itself?
CAPEX difference (PLN 22.1M) will be
paid in less then 6 years!
The full chain CCS demonstration plant, captures and stores the CO2 from 250MW (175 tonnes of CO2/h) of net electricity generation unit, with 100km CO2 pipeline, solvent: 30 wt% MEA, CO2 recovery: ca. 90%
29
Block diagram of demo CCS PLANT
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ChłodzenieOdsiarczanie
Dmuchawa AbsorberWymiana ciepła
ChłodzenieRegeneratorRekupertor
Chłodzenie CO2 Sprężanie Osuszanie TSAASR ASR
AGR
AN
AGR
AN
Reclaimer
Wyparka
Oczyszczony AGR
AGR
AGR AGR
Spaliny
Gazoczyszczony do
komina
Woda do oczyszczalni
Roztwór odsiarczający
Zużyty roztwór odsiarczający
Kondensat Para
Para Kondensat
ChemikaliaZużyty roztwór amin
Woda chłodząca zasilanie
Woda chłodząca powrót
CO2
Do zatłaczania
1
Kondensat
4 7 8
6
910111216
3
Woda demin do uzupełnienia
Wodachłodząca zasilanie
Woda Chłodzącapowrót
1314
5
Kondensat
Odsiarczanie Usuwanie CO2 Sprężanie CO2
Odsiarczony gaz do komina
2
Woda do oczyszczalni
15
Amine scrubbing Desulfurization CO2
compression
Integration with Power Plant
Demo Plant Capacity = 175 tonnes of CO2/h
The Pilot Plant research summary
31
• The pilot plant campaigns successfully demonstrated reliable operation allowing the removal
of over 80 000 kg of CO2 from real flue gas (2000h).
• The energy requirement for solvent regeneration was found about 3,16 MJ/kgCO2 (gross value) with 90%
CO2 removal efficiency .
• Experimental data was presented to verify effectiveness of the modifications which were up to this time
presented mainly through modelling.
• Presented modifications resulted in an increase of CO2 recovery ranging from 4% to 16% while reducing
the reboiler heat duty up to 16%.
Parameter Value
Number of campaigns 29
Number of tests 360
Operation time 2000 h
CO2 removed approx. 80 000 kg
Intermittent
Renewable Energy
Electrolyser
SNG
CO2 Capture
CO2
Surplus
Coal power
plant
H2
O2
H2O
H2O
H2O
Natural gas
network
Domestic uses
Fuels
Transportation
Chemical
market
Several markets
Exis
tin
g in
fra
str
uctu
re
Solar PV
Wind turbine Water electrolysis
Modular structured
reactor
CO2 hydrogenation
32
New project – CO2 methanation system for electricity storage through SNG production
Project Partners:
TAURON Wytwarzanie
CEA
ATMOSTAT
AGH University of Science and Technology
Institute for Chemical Processing of Coal
RAFAKO S.A.
West Technology & Trading Polska Sp. z o.o.
Cooperation opportunities in low carbon energy
33
• Pre and post combustion pilot plant tests (LCE-24-2016)
• Biomass gasification pilot plant tests (LCE-19-2016-2017)
• Implementing post combustion CCS in other than Energy Sector (LCE-
29-2017)
• Deep cleaning of a captured CO2 stream (from ppm to ppb) (LCE-25-
2016)
• Utilisation of captured CO2 as a feedstock (LCE-25-2016)
• Geological storage with enhanced gas recovery (LCE-30-2017)
E-mail: [email protected] Internet: www.ichpw.zabrze.pl
Research team:
dr inż. Aleksander Sobolewski
dr inż. Krzysztof Dreszer
mgr inż. Józef Popowicz
dr inż. Lucyna Więcław Solny
mgr inż. Adam Tatarczuk
mgr inż. Marcin Stec
mgr inż. Tomasz Szczypiński
mgr inż. Piotr Kolon
mgr inż. Dariusz Śpiewak
mgr inż. Tomasz Spietz
mgr inż. Aleksander Krótki
mgr inż. Andrzej Wilk
Industrial partners team:
dr inż. Stanisław Tokarski – TAURON Polska Energia SA
mgr inż. Janusz Tchórz – TAURON Wytwarzanie SA
mgr inż. Sławomir Dziaduła – TAURON Wytwarzanie SA
inż. Stanisław Gruszka – TAURON Wytwarzanie SA
mgr inż. Jerzy Janikowski– TAURON Polska Energia SA
mgr inż. Janusz Zdeb – TAURON Wytwarzanie SA
Project manager:
dr hab. inż. Marek Ściążko, prof. nadzw.
STRATEGIC RESEARCH PROGRAM – ADVANCED TECHNOLOGIES FOR ENERGY GENERATION TASK No. 1 – „Advanced technologies for energy generation: Development of a technology for highly efficient zero-emission coal-fired power
units integrated with CO2 capture”
Project co-financed by the National Centre of Research and Development in the framework of Contract SP/E/1/67484/10, dated 05 May 2010r.
34
We invite you to take a virtual tour of the Clean Coal Technology Centre: http://ichpw.wkraj.pl/#/65563/0
and to watch the movie about the Institute: http://koala.ichpw.zabrze.pl/video/Institute_for_Chemical_Processing_of_Coal.mp4
STRATEGIC RESEARCH PROGRAM – ADVANCED TECHNOLOGIES FOR ENERGY GENERATION TASK No. 1 – „Advanced technologies for energy generation: Development of a technology for highly efficient zero-emission coal-fired power
units integrated with CO2 capture”
Project co-financed by the National Centre of Research and Development in the framework of Contract SP/E/1/67484/10, dated 05 May 2010r.
35
36
Tauron’s Pilot Plant - That's one small step for [an] engineer,
one giant leap for Poles.
Thank you for attention
