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CO2 Capture
From Power Plant Flue Gas - A Simulation case study in Hysis Platform
Subhasish Mitra M.Tech Department of Chemical Engineering IIT Kanpur
Motivation:
Global warming triggers environmental concern over reduction of greenhouse gas emissions from industrial sources.
CO2 is major contributor to the global warming phenomenon due its abundance comparing to other green house gases.
Huge quantity of CO2 in flue gases released from power plants can be separated and utilized for various industrial uses.
Gas absorption process with amine based chemical reaction is recognized as most cost effective solution with proven track records.
Application of CO2:
Carbonated soft drinks & soda water, Leavening agents e.g. Baker’s yeast, Baking powder used in dough.
Used in pneumatic system for portable pressure tools. Good fire extinguisher.
Supercritical CO2 is a good industrial solvent, e.g. extraction of lipophilic organic compounds, extraction of caffeine from coffee etc.
In chemical industry for production of Urea, carbonates & bicarbonates and sodium salicylate.
Liquid CO2 as refrigerant (R774).
Oil recovery & coal bed methane recovery.
Combined power cycle:
Rankine cycle
Brayton cycle
Combined Power Cycle Effciency: ήcc= ή GT + ή ST - (ή GT )(ή ST )
Amine plant – simplified PFD:
Amine package introduction: •Two different amine packages are available in Hysis – Amine Package, DBR Amine Package. •Based on extensive experimental data on equilibrium acid gas (CO2, H2S, COS, CS2) solubility and kinetic parameters for the aq. alkanolamine solutions.
•Important! The package works only under specified set of operating conditions e.g. amine conc., temperature & acid gas partial pressure.
Amine package operating conditions: Alkanolamine
Amine conc.(wt%)
Acid gas partial pr (psia)
Temp (F)
MEA
0 – 30
1e-4 – 300
77 – 260
DEA,TEA, MDEA
0 – 30
1e-4 – 300
77 – 260
DGA
50 – 70
1e-4 – 300
77 – 260
DISoA
0 – 40
1e-4 – 300
77 – 260
Data not correlated for H2S and CO2 loadings > 1.0 mole acid gas/mole amine
Amine package details: Methods of calculation: • Liquid: VLE (vapor liquid equilibrium) : Kent Eisenberg & Li Mather • Vapor: VLE (vapor liquid equilibrium) = Peng Robinson • Enthalpy/Entropy = Curve Fit
Underlying chemistry: Electrochemical reactions occur in the aq solution.
Power plant process simulation diagram: HP Steam turbine
LP Steam turbine
Steam condenser
Steam boiler Gas Turbine Block Flue gas to CO2 absorption unit
CO2 capture plant process simulation diagram: Amine regen tower
Amine absorption tower
Simulation figures: Power plant capacity
Available data:
Natural gas flow
400
MW
12480
m3/hr
Fuel air ratio
2.22
Compressor duty
154.6
MW
120
bar
110.6
MW
4
bar
LP steam turbine capacity
29.96
MW
Condensate pump capacity
2.832
MW
Heat input in boiler
445.2
MW
Rankine cycle efficiency
0.309
High Pr steam HP steam turbine capacity Low Pr steam
Compressor in
Compressor out
cp/cv
1.401
1.352
kavg
1.3765
pr increase ratio (rp)
30
Brayton cycle efficiency
0.606
efficiency (combined power cycle)
0.728
1-(1/rp )^(k-1)/k
Simulation figures (Contd): Total flue gas flow rate
48810
kmol/hr
Flue gas cooler duty
89.57
MW
Flue gas blower duty
29.37
MW
Blower after cooler duty
45.87
MW
Feed rate to amine absorption column
44010
kmol/hr
CO2 molar flow into absorption column
2358.6
kmol/hr
CO2 molar flow from absorption column
67.12
kmol/hr
% removal of CO2
97.15
Absorption column operating pr
200
kpa
Total lean MEA flow into absorption column
79220
kmol/hr
Fresh make up lean MEA
292.8
kmol/hr
0.04233
MW
Regenerator pre-heater duty
80.00
MW
Regenerator column reboiler duty
110.5
MW
lean amine cooler duty
81.42
MW
lean amine pump duty
0.06197
MW
Total energy invested in the absorption unit
139.97
MW
Energy required per mole of CO2 scrubbed
5.00
MJ/kg
Rich amine pump duty
Absorption parameters:
% reduction of C O2
Pressure effect on % reduction of CO2
• CO2 absorption is enhanced as higher pressure however the advantage saturates at 300 kpa (not shown)
Total feed rate to absorption column changes as recycle increases
Keep a ratio set point of total amine feed into tower with feed flue gas
CO2 loading in amine crosses package limit (all streams’ color turn yellow)
Decrease amine conc. in fresh make up
Regenerator pressure profile
Change column bottom pressure to match column bottom temperature
Presence of vapor at rich amine pump inlet Stripper column convergence Very large %equilibrium approach for acid gas
Increase amine circulation rate Use spec for top temperature and recycle ratio Still Searching!
Wind up:
Combined power plant cycle gives more efficiency than the individual constituent cycle.
Setting up a CO2 capture plant sounds beneficial from both environment as well as economic point of view (pending techno-economic analysis)
Qualitatively the benefit is more tangible if energy consumed/mole of CO2 absorbed is further reduced (5MJ/kg as per present simulation) – thrust on selecting various amines to reduce circulation rate.
Regenerator tower energy requirement can be met by the HP ST exhaust obtained from power plant (discarding option of producing power from LP ST) which needs to be substantiated by the techno-economic analysis.
