beysel_asu_1stoxyfuel cottbus.pdf

8/11/2019 Beysel_ASU_1stOxyfuel Cottbus.pdf

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A proven Process applied to Oxyfuel

-

. .

1st Oxyfuel Combustion Conference

Cottbus, Sept 8th, 2009


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Agenda

1 Introduction

2 Air Separation Technologies

3 Potentials for Power Savings and Cost Reduction

o en a s or arge apac es an xygen eman or ew

Applications

5 Innovative Improvements at Cryogenic Air Separation

Bey/L/092009/Cottbus.pptLinde AG Engineering Division 2


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The Linde Group

The Divisions

Linde EngineeringLinde Gas

(Headquarter Munich, Germany)


50 000 employees Sales 17 billion US$2006


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Linde Engineering DivisionProduct Lines & Key Plant

Olefin Plants

Natural Gas Plants

LNG

NGL

LPG

Helium

Ethylene

Propylene

Butadiene

NRU Polymers

Air Separat ion PlantsHydrogen and Synthesis Gas Plants

Products:

Ox en

Products:

H2/CO/S n as

Nitrogen

Rare gases

Ammonia

Gas removal

Gas purification



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Carbon Capture Technologies (CCS)

- From the ASU Perspective -

Technology Process LindePortfolio

1. Pre-CombustionGasifi

ASUGas

cleaninCO Shif t

CO2Liquefaction

(Rectisol)Compression

Feedstock

Feedstock CO2

2. Oxyfuel

(Oxycoal)DeSOxBoilerASU DeNOx

CO2Liquefaction

&Compression

CO2

3. Post-CombustionDeSOxBoiler DeNO

x

CO2 capture&

Com ression

Feedstock


CO2


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Air Separation Plants

Simplif ied Air Separation Process


Air compression,

-precooling and -purification

heat exchange, refrigeration,

rectification and internal compression

product

distribution


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Alternative Air Separation Technologies

Cryogenic Air Separation (ASU)

the principles invented one century ago (Dr. Carl von Linde)

commercialized for industrial application in a wide range the source for Industrial Gas Companies supply schemes

Continuous development and improvement , >25% power saving possible

Polymeric Membranes and Moleculare Sieves (PSA, VSA)

advantageous for small volumes - at lower purities

produced at ambient temperatures and as needed on-site

Oxygen Production by Chemical Air Separation (MOLTOX)

Developed and pilot tested by Air Products with DOE funding in early 1990s

>40% power saving predicted, compared with cryogenic processes

Status and future of the process unknown (material- and corrossion problems)

High Temperature Ceramic Membranes (ITM)

Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding


150 tpd under development;

>30% power saving predicted


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Alternative Air Separation Technologies- Potentials to Reduce Power Consumption and





High ++




medium+



>40% power saving predicted, compared with cryogenic processes?








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Alternative Air Separation Technologies

- Potentials to Supply Large Product Flows





High ++




low



>40% power saving predicted, compared with cryogenic processes?








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Typical Oxygen Demand for New Applications

New Applicat ions Capacity [MW] Oxygen [tons/day ]

IGCC (demo) 250 - 300 MW - 2.0001)

IGCC, Oxyfuel (demo) 300 - 600 MW 2.000 - 5.000 1)

CTL Pol eneration ro ect 1500 MW

25.000 1)

GTL (demo) 12.000 bpd 2.500 2)

GTL (commercial 35.000 bpd 7.000 2)

scale)

GTL (commercial

scale)

140.000 bpd 30.000 2)

Cryogenic ASUs: Single train sizes with a capacity of 5.000 tons/d are available

1) Low uit ox en 99,5%


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Cryogenic Air Separation Capacity Increase


5 kg/h

(0,1 ton/day)

1,250 Mio kg/h

(30.000 ton/day)


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Air Separation Plants Shell Pearl GTL ProjectQatar

.



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Air Separation Plants Shell Pearl GTL ProjectQatar

.



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Large Tonnage ASUColdbox Shipment for Pearl GTL project



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Tonnage Air Separation PlantsMega Plants for new Applications



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Air Separation Process Advanced AlternativeDesign

GOX

GPOWER

Power Wrme/Abwrme

5.2-5.7 bar

PGAN

Vorkhlung Adsorber AIR5.5-6

bar

1.2-1.3 bar1

.05bar

Wrm

etausc

her

os

ter

rbine

1r

N

iederdruc

kko

lonne

Restgas

Bo

Tu

1 K

on

densa

to

G

Oxygen: 95%, gaseous, at ambient pressure

Hoc

hdruc

kko

lonne

UK

.3-5.8

bar

Features:

reduced energy consumption/power recovery by

expanding


PGAN

heat integration


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Air Separation ProcessAdvanced Alternative Design ( Dual Reboiler -

GOX

bar

ar

erdruc

kko

lonne

4.

1.0

5

Wrme

tausc

her

Boos

ter

Turb

ine

ensator

2

Nie

KG

Kon U

on

densa

tor

1

Hoc

hdruc

kkolonnK

4.3

bar

, ,

Features:

reduced rocess air ressure


reduced power consumtion


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Air Separation ProcessAdvanced Alternative Design (3-column Design)

GOX

.5bar

bar

4

1.0

5

Wrme

tausc

her

Boos

ter

Turb

ine

K

on

densa

tor

2

erdruc

kko

lonne

2

U

KG

Nied

nsa

tor

1

ckko

lonne

1

Hoc

hdruc

kkolo

nn

Kon

de

4.3

bar

Niede

rdr, ,

Features:

reduced rocess air ressure


reduced power consumtion


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Air Separation UnitsCryogenic Oxygen / Specific Energy

Conventional Process Schemes / - Applications

kWh/Nm 1) kWh/Nm 2) kWh/t (metric ton) 3)kWh/t (short ton)

(= 907,2 kg) 3)

Conversion Figures:

1 O,95 699 635

0,35 kWh/Nm O,33 kWh/Nm 245 kWh/t 222 kWh/t

Conventional ASU, Oxygen Purity >99.5%


1)

used by ASU vendors (Linde et al) and commonly used for process calculation

2)

used by Gas Companies

3)

1 Nm= 1,429 kg


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Air Separation UnitsCryogenic Oxygen / Specific Energy

Advanced Process Schemes for New Applications, e.g. IGCC,Oxyfuel, IGSC

kWh/Nm 1) kWh/Nm 2) kWh/t (metric ton) 3)kWh/t (short ton)

(= 907,2 kg) 3)

Advanced, energy optimized ASU, 95 % Pur ity Oxygen

0,25 0,237 175 159

Power consumption reduced by > 25% !!


Above Figures are related to 100% Oxygen (contained Oxygen), normal ambient conditions for design: 20C, 15C CW, 60% rel. humidity, at sealevel


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Air Separation PlantsMega Plants for new Applications

Power Plant Specific Requirements and their consequences



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Air Separation Units for Power Plants SpecificRequirements

Specific Power Plant Requirements:

lowest possible power consumption

CAPEX and OPEX optimization

operation range from 60 to 105%

load change > 2% per minute

oxygen purity 95%

low product pressure

Differences between Power Plant Standards and conventional Industrial Gases


Standards


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Air Separation UnitsSpecific Requirements for Power Plants

Design margin of 5%,

turndown to 63%,

design for maximum ambient conditions,

are not to be considered for design,

potential for further power saving of 8%.



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Air Separation Units for Power PlantsAir Compression Efficiency

(For a typical ASU)

Turndown Power at motor terminal Additional power

Comparison

75 to 80% 18 500 kW 100 %

63% 19 100 kW + 600 kW 103 %

56% 19 500 kW + 1000 kW 105 %



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Air Separation Units for Power PlantsAir Compression Efficiency

Ambient Air Temperature -17C 9C 30C 33C

Effective Air Volume Flow 91% 100% 107% 109%

plus 5% design margin



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Load change scenario: Ramping of processparameters

Load change scenario - conventional process scheme considered

ramping > 4 %/min

350000

400000

0,99

1

250000

300000

0,96

0,97

0,98Oxygen Purity

150000

200000

Nm/h]

0,94

0,95

O2[%]

Mair

MGOX

O2_%

50000

100000

0,91

0,92

0,93


0

0 2000 4000 6000 8000 10000 12000 14000

Time [sec]

0,9


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Air Separation Units for Power PlantsSummary, Low Power Consumption

Steps to low power consumption of ASU:

apply highly efficient air separation process

select appropriate compressor model

identify possibilities for power/heat integration

pick advantageous driver option

check operations requirements carefully (turn down, design margin, etc.)



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Advanced Cryogenic Air Separation- innovative improvements for new applications

Advanced Structured Packings instead of sieve tray columns available

reducing pressure drop , increasing turndown capacity

Advanced rocess control s stems, ALC AutomaticLoadChan e

available

Dynamic Simulation

Compressors with higher efficiency, larger turndown range development

High efficient Heat Exchangers available

Advanced process schemes 1) available

1) Large Scale Low Purity Oxygen Requirement (e.g. 95%) - is a novalty in Cryogenic ASU applic


leads to a step change energy reduction compared to traditional applications !


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Linde Engagement in CCS Oxyfuel

Linde has built an air separation plant and a CO2 purification and liquefactionplant for Vattenfalls first oxyfuel pilot plant for coal-based power generation

Linde

with CO2 capture.

Oxyfuel CombustionCO2 to Storage

H2O Condensation CO2 LiquefactionAir Separation Uni t

Steam

N2 Free Flue Gas

Oxygen

Combustion Power Generation

CO2 Recycle


Feedstock Steam Generation Heat Recovery


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Groundbraking Ceremony May 2006



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Oxyfuel Pilot Plant Schwarze Pumpe 3-D Model



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Oxyfuel Pilot Plant Schwarze PumpeOfficial Inauguration and start-up: Sept. 9th 2008

Boiler

Dust filterASU

DSU

FGC


CO2 plant Control room


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Vattenfall Oxyfuel Powerplant Schwarze PumpeLinde Scope: ASU, CO2 Plant;



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Vattenfall Oxyfuel Powerplant Schwarze PumpeASU with LCO2 Tank



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Vattenfall Oxyfuel Powerplant Schwarze PumpeCO2 Plant with LCO2 Tanks



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Linde Engagement

Coal or petcoke gasif ication, Oxygen for CO2-free power

generation, Hydrogen for refinery applications, LNG, and Gas To

Liquids, are all energy related development trends where Linde is

- .

Linde - the Pioneers of Air Separation we are able to respond to

the challenge of producing cleaner fuel & energy for the growing

wor w e eman .

(Dr. Aldo Belloni , CEO-Linde)



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for your attention.

beysel_asu_1stoxyfuel cottbus.pdf

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