PURIFICATION PROCESS TECHNOLOGY OF COAL BED METHANE (CBM) Abstract. Introduction
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1 PURIFICATION PROCESS TECHNOLOGY OF COAL BED METHANE (CBM) DaeHo Ko, SungWook Row, EuiSub Ahn, WangYun Won Plant Technology Team GS Engineering & Construction Seoul , Korea Abstract This work focuses on the development of an energy efficient hybrid gas separation system to purify Coal Bed Methane (CBM) gas consisting of mainly methane and other impurities such as carbon dioxide, ethane, and so on. We compared three main separation processes absorptions, adsorptions, and membranes and adopted the adsorption and membrane processes as candidates for the conceptual design work, considering the pilot plant scale and utilization purposes. Based on the case studies of several process configurations, the optimal conceptual design is suggested for the CBM purification by adopting the hybrid system of PSA and membrane processes, which is energy efficient and shows good purity and recovery. Introduction Natural gas adsorbed on coal beds underground is called Coal Bed Methane (CBM). The CBM compositions are mainly methane and other impurities such as carbon dioxide, ethane, and so on. The compositions may vary according to the CBM site. To use the CBM as an energy source, gas treating processes to remove sour gas may be required depending on the purposes of the natural gas utilization. This study focuses on the development of the energy saving and flexible separation / purification processes of CBM. At first, we compared three main methods for separation processes, i.e., absorptions, adsorptions, and membranes through simulations and experiments in order to select suitable processes. Our simulation of absorption process using Pro-II software shows that the sour gas mole fractions of CO 2 and H 2 S in the purified gas stream are less than 10 and 5 ppm respectively when the feed gas (CH 4 rich gas) stream consists of CO 2 (~10%) and H 2 S (~5%). The absorption processes using amine as a solvent have an excellent purification performance and is generally adopted in the large scale gas treatment plants requiring a highly purified gas product. The simulation (gproms software) and experiments of a pressure swing adsorption (PSA) process were performed. When the adsorbent is carbon molecular sieve (CMS) and the feed gas consists of 10% CO 2 and 90% CH 4, the purified product purity is more than 98% and the recovery is about 80%. The purity can be enhanced up to more than 99% CH 4. The adsorption process using CMS has a very good purification performance and is generally used in the small to medium large scale gas treatment processes. We checked membrane performances through the simulation (gproms software) and experiments. When the feed gas consists of 10% CO 2 and 90% CH 4, the purified product gas (CH 4 ) has more than 97% purity. The membrane process has a relatively low purification performance but a simple and compact configuration compared with the other processes such as the absorption and adsorption processes. The membrane process is mostly used in a small scale process but recently a somewhat large scale membrane process is under the development and commercialized. 1
2 This study focuses on the two processes adsorption and membrane processes as candidates for the conceptual design work, considering the utilization purposes and amount of the purified CBM gas as well as transportation problems of the pilot plant facilities to the corresponding site in our R&D program. Here, the scale of CBM feed gas is expected as a 10~2500 Nm 3 /hr. With the two processes of adsorption and membrane processes, we performed a conceptual design study for the gas treatment by comparing eight types of candidate process configurations. The candidate processes involve the single processes (PSA only or membrane only) and hybrid processes consisting of PSA and membrane systems. The power consumptions per the corresponding product (purified gas) flow rate are compared, and suitable hybrid process configurations with recycle streams have been chosen in view of power consumption, purity, and recovery of the product gas. In summary, the conceptual design is performed for the CBM purification processes adopting PSA and membrane processes, resulting in the development of the energy efficient hybrid system of PSA and membrane, which can achieve more than 97% purity and 95.5% recovery of CH 4. Also we checked the pressure vacuum swing adsorption process that can acquire more than 97% purity and 90% recovery of CH 4. Consequently, a basic design package for the CH 4 gas purification process was developed to construct a pilot plant to purify CBM feed gas. The next sections describe the adopted PSA and Membrane systems briefly which are used in simulations and experiments to do conceptual design. Process Description The adopted pressure swing adsorption (PSA) process consists of four adsorption beds and has 12 operating steps as shown in Table 1. The adsorption process makes use of the adsorption characteristics, and the PSA is competitive in view of energy consumption and maintenance cost, and applied as gas purification plant in most industries. It removes impurities from feed gas by using the difference of adsorption amount of each gas depending on pressure difference. Table 1. 4 bed 12 operation step PSA Step Bed1 AD EQ1 - EQ2 BD PU EQ2 EQ1 BF Bed2 EQ1 BF AD EQ1 - EQ2 BD PU EQ2 Bed3 BD PU EQ2 EQ1 BF AD EQ1 - EQ2 Bed4 EQ1 - EQ2 BD PU EQ2 EQ1 BF AD Here, AD: Adsorption step EQ1 & EQ2: Equalization step In the step between EQ1 and EQ2, the valves of upper and lower side are closed. BD: Blowdown step. This step is called depressurization step from equalization pressure (EQ2) to atmospheric pressure by closing the product end valve and opening feed and valve. 2
3 PU: Purge step. This step is called regeneration step by purging (flowing the product gas through the adsorption bed (P/F ratio < 0.5 or lower)). BF: Backfill step. This step is called pressurization step by filling product gas into adsorption bed. The Membrane Section will do pre-treatment or post-treatment of PSA processes depending on the process configurations, that is, will separate CO2 (up to about 3%~10%, max) from the sour gas (CO2 rich gas), and produce CH4 rich gas. It will be chosen among the hollow fiber membrane processes. Recommendation for Pilot Plant Design Configuration In this study, the followings are assumed for brief comparison of power consumptions. - The discharge temperature of compressors is the same as the suction temperature by cooling the compressor for the prevention from the overheating. - The pressure drop between the feed and retentate stream of membrane systems is negligible. Because the power consumptions are mainly dependent on the compressor and vacuum pump, power consumptions are calculated by using the required theoretical power of compressors and vacuum pump. Here, the adopted feed flow rate is 100Nm 3 /hr. Judging from the comparison through brief calculations, the hybrid systems consisting of membranes and PSA have lower power consumptions per unit product flow rate than single systems (PSA only or Membrane only systems). Also the hybrid systems with recycle streams have higher the purity and recovery of product gas than single systems. Among the hybrid systems, the hybrid system of Figure 1s (Figure1.1~Figure1.2) is the best in view of the power consumption and the purity and recovery of the product (methane). Smaller power consumptions are expected if the zeolite type adsorbent is adopted in PSA systems. But the zeolite type is vulnerable to humidity. In the humid weather, CMS type adsorbent is recommended for PSA systems. If the methane composition in CBM feed stream is very low (~60%), the system of Figure 2s (Figure2.1~Figure2.2) can be alternative process designs. Because the membrane pre-treatment section can increase the methane composition to about 90% and then PSA system can purify the gas up to 97% (or even more). The Figure 2.2 can achieve the high purity and recovery of the product by recycling the two streams which are the retentate gas from the second membrane section and purge gas from the PSA section. 3
4 Figure 1.1: Hybrid PSA (adsorbent: Zeolite) & Membrane with recycle stream when methane composition of CBM is about 90% Figure 1.2: Hybrid PSA (adsorbent: CMS) & Membrane with recycle stream when methane composition of CBM is about 90% 4
5 Figure 2.1: Membrane Recycle with PSA System when the low methane composition of CBM (~60%) Figure 2.2: Hybrid Membrane and PSA with Two Recycle Streams when the low methane composition of CBM (~60%) 5
6 Conclusion The hybrid systems consisting of membranes and PSA have lower power consumptions per unit product flow rate than single systems (PSA only or Membrane only systems). Also the hybrid systems have higher the purity and recovery of product gas than single systems. Among the hybrid systems, the process configuration of Figure 1s (Figure1.1~Figure 1.2) is the best in the power consumption and the purity and recovery of the product (methane). Smaller power consumptions are expected if the adsorbent is the zeolite type in PSA systems; however, the zeolite type is vulnerable to humidity. Thus CMS type adsorbent is recommended for PSA systems in humid weather environments. If the methane composition in CBM feed stream is very low (~60%), the Figure 2.2 can be another alternative process design. Because the membrane pre-treatment section can increase the methane composition to about more 90% and then PSA system can purify the gas up to 97% (or even more). The process configuration of Figure 2.2 can achieve the high purity and recovery of the product by recycling the two streams which are the retentate gas from the second membrane section and purge gas from the PSA section. Acknowledgement This research was partially funded by the Korea Evaluation Institute of Industrial Technology (KEIT) of Ministry of Trade, Industry & Energy (MOTIE) as a national research project in Korea. The authors appreciate Daesung Industrial Gases Co., Ltd. and Gens Engineering in the experiments and discussions on PSA, and Airrane in those on membranes. References 1. Seth P. Knaebel, Daeho Ko, and Lorenz T. Biegler (2005), Simulation and Optimization of a Pressure Swing Adsorption System: Recovering Hydrogen from Methane, Adsorption 11, Daeho Ko, Ranjani Siriwardane, and Lorenz T. Biegler (2005), Optimization of Pressure Swing Adsorption and Fractionated Vacuum Pressure Swing Adsorption Processes for CO2 Capture, Ind. Eng. Chem. Res., 44, Xuezhong He, Jon Arvid Lie, Edel Sheridan, May-Britt Hägg (2009), CO2 Capture by Hollow Fibre Carbon Membranes: Experiments and Process Simulations, Energy Prodedia 1,
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