CO 2, its Contaminant s, and their Treatment during Compression in OxyFuel Applications

Transcription

1 MAN Turbo Engineering the Future Since CO 2, its Contaminant s, and their Treatment during Compression in OxyFuel Applications MAN Turbo AG R. W. Allen < 1 >

2 Product Information CO 2 Compression Process Integration Experience OxyFuel Applications 2

3 Axial Compressors Suction flow rates up to 1.5 million m³/h Max. discharge pressure up to 25 bar Fuel gas Liquefied natural gas Fluid catalytic cracking GTL Blast furnace gas Coal / oil gasification Air storage Air separation Methyl Tertiary Butyl Ether Nitric acid Terephthalic acid Flue Gas 3

4 Centrifugal Compressors Suction flow rates up to 660, m 3 /h Max. discharge pressure up to 1000 bar Natural gas Associated gas Pipeline Refinery Ammonia Nitric acid Ethylene Refrigeration processes Air separation Methanol Oxygen Top gas 4

5 Integrally-geared Compressors Suction flow rates up to 350, m 3 /h Max. discharge pressure up to 225 bar Ammonia Fuel gas CO 2 compression Fluid catalytic cracking Urea Air separation Refinery / Petrochemicals Nitric acid Syngas Terephthalic acid Steam 5

6 Process Gas Screw Compressors Suction flow rates up to 100, m³/h Max. discharge pressure up to 50 bar Mining Chemicals Iron & Steel Oil & Gas Petrochemicals Dust Laden Gases 6

7 Steam Turbines Live steam up to 130 bar and 570 C Power output up to 120 MW Generator drive Mechanical drive 7

8 Process Gas Expanders Max. inlet pressure 65 bar Max. inlet temperature 760 C Power output up to 30 MW Energy recovery for: Fluid Catalytic Cracking Top gas Nitric acid Terephthalic acid IGCC / OxyFuel 8

9 Product Information CO 2 Compression Process Integration Experience OxyFuel Applications 9

10 History UNTIL THE MID 1990 s THERE WERE ONLY TWO WAYS TO COMPRESS CO 2 TO ~200 bar, i.e. MULTI- STAGE RECIPROCATING COMPRESSORS OR, MULTI-CASING CENTRIFUGAL COMPRESSORS. IT WAS AT THIS TIME THAT MAN TURBO INTRODUCED THE SINGLE BLOCK, MULTI-PINION, INTEGRALLY GEARED COMPRESSOR FOR THIS SERVICE IN A RUSSIAN UREA PLANT. DUE TO ITS LOW POWER REQUIREMENT, AND LOWER CAPEX, THE INTEGRALLY GEARED CO 2 COMPRESSOR IS TODAY, THE STANDARD SOLUTION FOR UREA FERTILISER PLANT APPLICATIONS. 10

11 Multi Shaft Gear Compressor for UREA 10-stage Integrally Geared Compressor (Wet CO 2 - Mix) for Urea Synthesis Type RG Flow: m³/h Pressure: 1.04 bar bar Power: kw 11

12 T / S Diagram NOVAZOT UREA Plant Compression Characteristic Pressure p in bar ,0 1,0 0,5 0,1 0, D S Tempera ature T in C 0,01 bar ,8 5,0 5,2 5,4 5,6 5,8 6,0 6,2 6,4 6,6 6,8 7,0 E n tro p y s in k J /(k g K ) 12

13 High Pressure CO 2 Compressors Sensitivity of Real Gas Factors for Various Gases 13

14 CO 2 Data & Influence of Impurities The triple point for a CO 2 mixture containing 4% N 2 increases from 73 bar 31 o C for CO 2 to 82.3 bar 26.6 o C Other contaminents have similar influences, some greater than others; H 2 has a major influence on the properties of the mixture! A new handbook in preparation by the CCS a (Carbon Capture & Storage Association) will cover these issues. courtesy 14

15 Performance Map NOVAZOT UREA Plant 10 Stage Design, IGV Control Calculated according to the Lee-Kessler-Plöcker (LKP) method 15

16 Integrally Geared Compressor Design UREA Plant Applications : HP CO2 Compressor RG 040/08 8-stage integrally geared compressor wet-co 2 / UREA plant Type RG Flow: m³/h Pressure: bar Power: kw Packaged Compressor Design on steel structure with close coupled inter-coolers for easy handling and installation. 16

17 Why Gear Type Compressors? THE MULTI-CASING, IN-LINE, CENTRIFUGAL COMPRESSOR TRAIN HAS THE DISADVANTAGE THAT, WHEN USED ON A GAS SUCH AS CO 2, ONLY THE FIRST FEW STAGES OPERATE NEAR THEIR OPTIMUM EFFICIENCY. THIS RESULTS IN A HIGH CAPEX / HIGH OPEX SOLUTION. THE INTEGRALLY GEARED CENTRIFUGAL COMPRESSOR HAS THE ADVANTAGE THAT EACH PAIR OF IMPELLERS CAN BE SELECTED FOR OPTIMUM PERFORMANCE. THIS LEADS TO <50% OF IN-LINE COMPRESSOR STAGES. IN ADDITION COOLING CAN BE INTRODUCED BETWEEN STAGES. THE INTEGRALLY GEARED COMPRESSOR HAS THE HIGHEST EFFICIENCY AND A LOWER CAPEX. 17

18 Integrally Geared Compressors Advantages All components in contact with wet corrosive gas mixtures, can be manufactured in acid resisting materials. Pinion shaft arrangement. Gearbox can be arranged with up to four pinion shafts driven from a single bull wheel. 18

19 Machine Materials FOR CO 2 APPLICATIONS AN EROSION/CORROSION RESISTANT MATERIAL IS SELECTED FOR THE IMPELLERS I.E. :- x3 CrNiMo 13.4 FOR WET CO 2 APPLICATIONS SUCH AS OXYFUEL, THE STANDARD VOLUTE MATERIAL IS UPGRADED TO: x3crnimo

20 Product Information CO 2 Compression Process Integration Experience OxyFuel Applications 20

21 Typical Compressor Performance CO 2 Compression 2 Integrally geared centrifugal compressors Suction = 1 bar abs* Discharge = 200 bar RG * SUCTION PRESSURE HAS A DIRECT INFLUENCE ON COMPRESSOR SIZING, POWER CONSUMPTION, & CAPITAL COST. 21

22 CCS Compression Duties Influence of Capture Pressure CO2 compressors with different suction pressures Influence of Capture (suction) Pressure on compressor size, power consumption and capital cost. RG size % % 80% Charts drawn on the RG Framesize basis of constant mass 0 flow (66.4 kg/s), and a suction pressure bara final discharge pressure of 180 bar abs. RG Type Size coupling power Cost Curves plotted for capture pressures of 1.1 & 1.7 bar abs (typical of amine scrubbing, Selexol, Rectisol, etc.), 5.0 bar abs (e.g. chilled ammonia), and 10 bar abs (IGSC with 100% CO 2 capture). tercoolers nu umber of stages and int % 52 % CO2 compressors with different suction pressures suction pressure bara 3 55% 37 % 5 Number of impellers number of intercoolers 22

23 Typical CO 2 Compressor Scheme with De-Hydration Inlet (100% flow) 20% Hot (regen) Recycle Discharge (100%flow) AS-valve1 AS-valve2 AS-valve3 WET STAGES DRY STAGES %flow IGV NOTE Intercoolers 1,2, & 3 not shown for clarity Cooler/Sep. Condensate Removal Cooler/Sep. 100%flow Fixed bed drier Aftercooler 23

24 CO 2 Purification during Compression Removal of SO x,no x and Hg THE INTEGRALLY GEARED CENTRIFUGAL COMPRESSOR ALLOWS THE EASY INTRODUCTION OF SIDE-STREAMS, GAS DE-HYDRATION AND OTHER PROCESS STEPS DURING THE DIFFERENT STAGES OF COMPRESSION! e.g. SO x removal NO x removal Wet CO 2 stream with contaminants Dilute HNO 3 Dilute H 2 SO 4 removed in HNO 3 & Hg condensate removed in condensate 24

25 High Capacity Compressor Trains High capacity CO 2 Compressor with Steam Turbine Drive COMPRESSOR TYPE RG140/05 (SHOWN) MAX. NO. OF STAGES : 7 MAX. POWER RATING : ~50 MW TURBINE DRIVE SPEED : OPEN TURBINE TYPE : CONDENSING EXHAUST ARRGT. : AXIAL FOR UTILITY POWER STATION APPLICATIONS THE STEAM BALANCE FOR THE MAIN POWER PLANT SHOULD INTEGRATE THE STEAM REQUIREMENTS FOR THE MAIN PROCESS COMPRESSORS (ASU & CO 2 ) 25

26 High Capacity Compressor Trains 3500 TPD AIR SEPARATION TRAIN DURING ERECTION 2 x 3500 TPD ASU TRAINS (EACH WITH A DOUBLE - ENDED 80 MW STEAM TURBINE DRIVER) DURING WORKS PACKAGING AND TESTING PRIOR TO DESPATCH. 26

27 Energy Integration TO ACHIEVE OPTIMUM PLANT EFFICIENCIES, ENERGY INTEGRATION SHOULD BE CONSIDERED. WHILST RECOVERY OF LOW GRADE HEAT FROM THE CO 2 COMP INTERCOOLERS IS DIFFICULT, THIS IS OF SIGNIFICANT IMPORTANCE FOR OXYGEN BASED PROCESSES WHERE ASU AIR COMPRESSION HEAT CAN BE RECOVERED IN AN ORGANIC RANKINE CYCLE. 27

28 Product Information CO 2 Compression Process Integration Experience OxyFuel Applications 28

29 CO 2 Pipeline Schemes Beulah Head Station : 45 MW Compression to 200 bar Operational since 1997 : 1,500,000 t pa CO 2 (initial) Current transfer rate : ~ 2,250,000 tpa Planned future rate : > 3,000,000 tpa Pipeline >200 miles North across the Canadian border 29

30 Dakota Pipeline Compressor during Works Testing 8-stage Integrally Geared CO 2 Compressor for Gas Transport & Injection Type RG Flow: m³/h Pressure: 1.15 bar bar Power: kw Total installed power : 45 MW in three compressor units feeding into the Beulah/ Weyburn 200 mile high pressure (~220bar) pipeline. 30

31 Dakota Pipeline Experience IN 1997, WHEN THE DAKOTA STATION WAS COMMISSIONED, THE TWO CO 2 COMPRESSORS OPERATED IN PARALLEL, JOINTLY FEEDING THE 200 MILE PIPELINE TO ENCANA AT WEYBURN. THE PIPELINE WAS DESIGNED TO OPERATE WITH THE CO 2 IN THE SUPER-CRITICAL PHASE TO MINIMISE THE TRANSMISSION POWER. IN 2007 A THIRD COMPRESSOR WAS ADDED IN BEULAH TO INCREASE THE INJECTION RATE AT WEYBURN; THIS NECESSITATED THE INTRODUCTION OF A BOOSTING STATION AT TIOGA, NORTH DAKOTA (APPROX. HALF-WAY ALONG THE LINE). 31

32 Dakota Pipeline Experience SINCE 1997, THE DAKOTA COMPRESSORS HAVE OPERATED WITH VERY HIGH AVAILABILTY. ALTHOUGH SOME TEETHING PROBLEMS DID OCCUR DURING EARLY RUNNING, THE SPECIALLY DEVELOPED CARBON RING SHAFT SEALS HAVE BEEN A GREAT SUCCESS. PARTICULAR TO THE BEULAH PROCESS PLANT, THE GAS COMPRESSED IS BONE DRY, AND COMPRISES ~97% CO 2, >1% H 2 S AND >1.5% HYDROCARBONS. SPECIAL MEASURES WERE TAKEN WHEN DESIGNING SG GTHE SYSTEM S CONTROL, O DUE TO THE USE OF FIN-FAN GAS COOLERS OPERATING IN LOW AMBIENT TEMPERATURES. 32

33 Product Information CO 2 Compression Process Integration Experience OxyFuel Applications 33

34 OxyFuel Applications MAN TURBO OFFER A COMPLETE SOLUTION FOR ALL THE COMPRESSION REQUIREMENTS ASSOCIATED WITH THE OXYFUEL PROCESS. MAN TURBO CAN ASSIST IN FULLY INTEGRATING THE CO 2 TREATMENT AND CONDITIONING STEPS WITHIN THE COMPRESSION PROCESS. HEAT INTEGRATION TECHNOLOGY IS ALSO AVAILABLE USING A WIDE VARIETY OF MAN TURBO - MACHINERY SOLUTIONS. MAN TURBO OFFER WORKS PACKAGING AND TESTING OF THE WORLDS LARGEST ASU & CO 2 TURBOMACHINERY TRAINS. 34

35 Thank you for your attention MAN Turbo Engineering the Future Since Engineering the future since MAN Turbo AG R. W. Allen < 35 >