update of the deployment of the km cdr process€¦ · update of the deployment of the km cdr...

Update of the Update of the Deployment of the KM CDR ProcessProcess

September 9th, 2015

Mitsubishi Heavy Industries, Ltd.Ch i l Pl t & I f t t Di i iChemical Plant & Infrastructure DivisionTakashi Kamijo

CONFIDENTIAL

© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Contents

1. MHI’s CO2 Capture Technologies & Experience2 p g p

2. 500 Metric TPD CO2 Capture Demonstration Plant in 2 pUSA

3. Project Status of World’s Largest CO2 Capture Plant from Coal-fired Power Plant2

4. Summaryy

© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2CONFIDENTIAL

11. . MHI’sMHI’s COCO22 CaptureCaptureT h l i & E iT h l i & E iTechnologies & ExperienceTechnologies & Experience

3© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

1.1 History of Development of MHI’s CO2 Capture Technology

1990 Started R&D activities with Kansai Electric Power Company (KEPCO)p y ( )

1991 Started a 2 ton per day pilot plant at KEPCO’s Nanko Power station

1994 D l f i hi d d i l “KS 1®” d “KM CDR P ®”1994 Development of proprietary hindered amine solvent “KS-1®” and “KM CDR Process®” with KEPCO

1999 First commercial plant in Malaysia ( 200 ton per day, to enhance urea synthesis from th CO d f f fl )the CO2 recovered from a reformer flue gas)

2002 Started a pilot test for coal-fired power plant at MHI’s Hiroshima R&D center

2003 Hi h ffi i D l t f i t ffi i t2003 High energy efficiency - Development of proprietary energy efficient process “Improved KM CDR Process“

2008 Fi t i l l t i Middl t ( 400 t d ) hi h “I d KM CDR2008 First commercial plant in Middle east ( 400 ton per day) which “Improved KM CDR Process” applied

2011 World’s first - Started 500 ton per day fully integrated CCS demonstration plant with Southern Company for a coal fired power plant at Alabama Power's James M BarrySouthern Company for a coal-fired power plant at Alabama Power's James M. Barry Electric Generating Plant

2014 World’s Largest - Received an order for a PCC plant of 4,776 ton per day for EOR mainly promoted by NRG Energy Inc and JX Nippon Oil & Gas Exploration

© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 4

mainly promoted by NRG Energy Inc. and JX Nippon Oil & Gas Exploration Corporation

CONFIDENTIAL

1.2 R&D, Pilot Plant and Engineering Head Quarters in Japan

Absorber 1 by 1 scale testAbsorber 1 by 1 scale test plant in Mihara

(400 MW equivalent)

tpd Matsushima pilot for testing coal fired flue gas g g

( 2006 ~ 2008)


f & f f CO

1.3 MHI - R&D Strength & Experience

Deployment of R&D Facilities for specific CO2 capture testing. More than 25 years R&D Experience

(A) R&D laboratories (MHI Technologies and Innovation Headquarters)(B) 2 TPD Nanko Osaka pilot plant from 1991(B) 2 TPD Nanko Osaka pilot plant from 1991(C) 1 TPD Hiroshima pilot plant(D) 0.2 TPD mobile test unit (E) Absorber 1 by 1 scale test plant in Mihara (400 MW equivalent)( ) y p ( q )(F) 10 TPD Matsushima pilot for testing coal fired flue gas(G) 500 TPD Barry CCS demonstration plant in Alabama, (25MW equivalent)

B C F G

2 TPD Nanko Pilot Plant(Kansai Electric Power Co )

1 TPD Hiroshima Pilot Plant(MHI’ R&D Center)

10 TPD Matsushima Pilot Plant(J-Power)

500TPD Barry Demonstration Plant(Southern Company)

6

(Kansai Electric Power Co.) (MHI R&D Center) (J Power) (Southern Company)

© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. CONFIDENTIAL

1.4 Scale Up R&D

Absorber 1 by 1 scale test plant in Mihara (400 MW equivalent)(World Largest CO2 Absorber Test factility)400 MW i l t fl fl (1 200 000N 3/h)400 MW equivalent flue gas flow (1,200,000Nm3/h)Liquid distribution tests were conducted for large rectangular AbsoberCFD FOR Gas FlowCFD FOR Gas Flow

32 mS i

Absorber

S i

Absorber

FanSpray pipes

FanSpray pipes

Recirculation PumpsRecirculation Pumps

7© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. CONFIDENTIAL

1.5 KM CDR Process®


Solubility of CO2 in KS-1 and MEA SolutionAmine Reaction Mechanism

1.6 Solvent Comparison KS-1TM V MEA

Mono -ethanol Amine (MEA)

Amine Reaction Mechanism

-Regeneration Region

sure

2R-NH2 + CO2 R-NH3+ + R-NH-COO-

Higher Higher

Sterically Hindered Amine (KS-1)

CO

2P

artia

l Pre

ss

MEAKS-1TM

Less

R-NH2 + CO2 + H2O R-NH3+ + HCO3

-

2R-NH2 + CO2 R-NH3+ + R-NH-COO-

gCO2

loading

gCO2

loadingMore efficient

regeneration# Key feature is main KS -1 reaction mechanism requires only 1 mole

of amine to react with 1 mole of CO 2 and H 2O# Key feature is main KS-1 reaction mechanism requires only 1 mole of KS-1 to react with 1 mole of CO2 and H2O

Absorption Region

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Less Solvent

use R-NH2 + CO2 + H2O R-NH3

+ + HCO3-

Deterioration of Product+4

%)

KS 1 Commercial

Corrosion Test Result

2 2CO2 Loading (mol.CO2/mol.Amine)

+2

+3

BLE

SA

LTS

(wt% KS-1 Commercial

MEA PilotKS-1 Pilot

76.4 93.0 MEA

Test 2Test 1

76.4 93.0 MEA

Test 2Test 1(Unit : mils per year)

Less HSSformed

+1+1

HE

AT

STA

B

3.6 3.1 KS-1

8.3 9.5 MEA + inhibitor

3.6 3.1 KS-1

8.3 9.5 MEA + inhibitor Less corrosion


BaseBase100 200 300 400 500 6000

(hours) Test condition : 130 in the presence of O2

CONFIDENTIAL

1.7 MHI’s Patent for CO2 Capture Technology

MHI’s worldwide granted and pending patentsIn the US : 82 granted, 78 pending (as of Nov. 2014)


1.8 MHI CO2 Capture Plants Commercial ExperienceWorld leading large scale post combustion CO2 capture technology licensor, with 11 commercial 2plants in operation from a variety of natural gas or heavy oil flue gas sourcesWorld’s largest CCS plant is under construction in Texas.

1999200 t/d Malaysia

CO2 Recovery (CDR) Plant –IFFCO Phulpur Unit (India)

CO2 Recovery (CDR) Plant –IFFCO AonlaUnit (India)

2005330 t/d Japan

2009450 t/d India

2006450 t/d India

IFFCO Phulpur Unit (India)

2006450 t/d India

IFFCO AonlaUnit (India)

2009450 t/d Bahrain

1999210 t/d Malaysia


2010400 t/d UAE

2010240 t/d Vietnam

2011340 t/d Pakistan

2012450 t/d India

2014500 t/d Qatar

CONFIDENTIAL

2.2. 500 Metric TPD 500 Metric TPD COCO22 CaptureCapture22 ppDemonstration Plant in USADemonstration Plant in USA


2.1 Project Outline

FULLY INTEGRATED carbon capture & storage project with CO2 storage, by SECARB and Owner, in a saline formation at a nearby oil field

Location: Alabama Power, James M. Barry, yElectric Generating Plant

Partners: Southern Company, MHI & EPRI

Flue Gas Source: Pulverized Coal Fired Boiler

CO2 Capacity:500 Metric Ton / Day

Process: KM-CDR Improved Process

Solvent: KS-1® solvent

Start Up: June 3, 2011

Status: 100% load since June 22, 2011CO2 injection started on August 20, 2012

World’s First CCS Project integrated with Amine-based Post Combustion Process and CO2 Injection


Post Combustion Process and CO2 Injection

CONFIDENTIAL

2.2 Specification of Demonstration PlantSouthern Company Plant Barry CO Demo Plant Item Description

Plant location Mobile County (Alabama, U.S.A.)

Southern Company Plant Barry CO2 Demo Plant

AbsorberFlue Gas

Plant owner Southern Company subsidiary Alabama Power

Process KM CDR Process®

AbsorberQuencher

Absorption liquid KS-1TM solvent

Plant scale Corresponding to 25 tt (MW)

Regenerator

CO2 compression & Dehydration unit Plant scale 25 megawatts (MW)

Flue gas amount 116,800 Nm3/h

& Dehydration unit

Flue gas

CO2concentration 10.1 mol%-wet

CO2 capture capacity

500 tonnes/day (150 000 tonnes/year)

gas inlet

capacity (150,000 tonnes/year)CO2 capture ratio 90 percent


World’s First Integrated CCS Plant from Coal-fired Power Plant to CO2 Injection

CONFIDENTIAL

2.3 Outcome of Demonstration (1/2)

1. Operation Status as of August 31th, 2014

Items Results

p g ,

Total Operation Time * hrs 12,400

Total Amount of Captured CO2 * metric tons 230,100

Total Amount of Injected CO2 * metric tons 115,500

© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 15Reference: Denbury, “SECARB - Plant Barry to Citronelle”,Knowledge Sharing Conference – Mobile, May 17, 2012

CONFIDENTIAL

Item Main Results

2.3 Outcome of Demonstration (2/2)Item Main Results

Initial Baseline Testing

• Verified that actual utility and solvent consumption were lower than the design but within the expectation (CO2 removal efficiency: 90%, CO2 capture rate: 500MTPD).

• Proven that KM-CDR® Process can follow the operation condition of CO2 injectiong p 2 j• Captured CO2 quality is within the criteria of the pipeline and CO2 injection site

Emissions and Waste Stream

• Successfully demonstrated amine emission reduction technologies under the various SO3concentration condition (2013)

Waste Stream Monitoring • Measured total Volatile Organic Compound (VOC) emissions and verified that the

commercial scale CO2 capture plant using KM-CDR® Process will be acceptable

Process P t i T t

• Verified operation performance under several controlled operating parameters changes Parametric Test and Performance Optimization

p p p g p g(2011-2012)

• Achieved 0.95 ton-steam/ton-CO2 by optimizing steam consumption (2011)

Dynamic • Carried out continuous control testing to optimize the operation condition with selfDynamic Response Evaluation Test

• Carried out continuous control testing to optimize the operation condition with self-developed dynamic simulator. The system successfully controlled the operation condition (Oct. 2013)

• Achieved 100,000 metric tons of CO2 injection without any operational issuesLong Term Impurities Influence Test

, 2 j y p• Verified that the amine emission increased as a result of higher SO3 loading (Oct.

2011) • Verified that the impurities were removed from the solvent by reclaiming operation (2012,

)

16

2013)


2.4 DOE Heat Integration System Demonstration PJ

ObjectivesObjectives- Quantify the energy efficiency improvements

to the CO2 capture process - Quantify the tangential benefits

• ESP performance• Increase SO3, Hg, Se capture• Reduce CCS solvent consumption

G O

Process Configuration- 25MW slipstream

• Reduce FGD H2O consumption

p- Integrated with 500TPD CCS Plant at Plant Barry- Circulate BFW between steam cycle,

CCS plant and High Efficiency System- Miniature ESP

ProgressBP1 (FEED, Cost estimate, Permitting) Completed( g) pBP2 (EPC) CompletedBP3 Work in Progress- Operations


- Field Testing Analysis

17CONFIDENTIAL

3. 3. Project Status of World’s Largest j gCO2 Capture Plant from Coal-fired PowerPlantPlant

CONFIDENTIAL


Road to F ll Scale Commercial Plant

3.1 MHI’s Scale-up Strategy

Full Scale5,000 TPD Large Scale

Demonstration 500 TPD

Road to Full Scale Commercial Plant

500 TPD

Small Scale Demonstration 10 TPD ScalePilotPilot

1 TPD Scale

Know-how and Lesson learned from 11 commercial plants Simulators (CFD etc.)from 11 commercial plants Large Scale experiences for FGD

• Large amount of flue gas • >200 commercial plantsCO2 Recovery (CDR) Plant –

IFFCO Phulpur Unit (India)CO2 Recovery (CDR) Plant –

IFFCO Aonla Unit (India)


3.2 Petra Nova CO2 Capture Plant for CO2-EOR (1/2)

The world’s largest CO capture and compression plant from coal fired power plantProject owner: Petra Nova, a partnership between NRG Energy, Inc. and JX Nippon Oil & Gas Exploration Corporation

The world’s largest CO2 capture and compression plant from coal-fired power plant

Absorber

Exploration Corporation

L ti NRG WA P i h P Pl t i

Regenerator

Flue GasQ

Location：NRG WA Parish Power Plant in Thompsons, TX.Flue gas source: 650MW coal-fired boiler

QuencherCO2 concentration: 11.5%CO2 capture capacity：4,776 TPD(240MW equivalent)CO2 capture ratio：90%CO2 Use : CO2 EORPipeline : 12inch diameter, Approximately 81miles

CO2 CompressorCooling Tower

yInjection Site: West Ranch oil field in Jackson County, TXOperation Start：4th Quarter, 2016


p ,

[Reference] U.S. Department of Energy “W.A. Parish Post-Combustion CO2 Capture and Sequestration Project Final Environmental Impact Statement Volume I” (Feb, 2013), DOE/EIS-0473

CONFIDENTIAL

C t d d d CO f W A P i h P Pl t ill b d li d b 80 il CO i li

3.2 Petra Nova CO2 Capture Plant for CO2 EOR (2/2)

Captured and compressed CO2 from W.A. Parish Power Plant will be delivered by 80 mile CO2 pipeline to the West Ranch oil field.

1.4 million metric tons of greenhouse gas will be annually injected into the West Ranch formation. It is expected that oil production will be enhanced from 500 barrels/day to approx 15 000 barrels/day It is expected that oil production will be enhanced from 500 barrels/day to approx. 15,000 barrels/day.


3.3 Block Flow Diagram of CO2 Capture Plant

KM-CDR®Electric Power

Steam

Cooling Water

[Reference] U.S. Department of Energy “W.A. Parish Post-Combustion CO2

22

[ ] p gyCapture and Sequestration Project Final Environmental Impact Statement Volume I” (Feb, 2013), DOE/EIS-0473


3.4 Project ProgressKey Progress• Signed EPC contract, Issued LNTP: Mar 2014

• Issued Final Notice to Proceed (FNTP): Jul 2014

Key Progress• Foundation work almost completed

• Structure work on going

• Construction start : Sep 2014 • Operation Start：4th Quarter, 2016

Main pipe rackMain pipe rack

Cooling TowerFlue GasQ h

Regenerator

Absorber

Quencher

Site Photo Site Photo ((2015/8/10)2015/8/10)g


3.5 Construction Progress Photos (1/2)


Tower Modules in lay-down area

CONFIDENTIAL

3.5 Construction Progress Photos (2/2)


3.6 Regenerator in Shop


55. Summary. Summary55. Summary. Summary


Summary

The MHI’s KM-CDR® process is applied to twelve (12) commercial CO2capture plants.

Southern Company and MHI carried out the 500 MTPD CO2 capture and storage demonstration project at Alabama Power’s Plant Barry. Over 230,000 metric tons of CO2 was captured and over 115,000 tons of CO2 was injected as of August 2014. This project became the world’s largest start to finish CCS demonstration project on coal fired flue gas.p j g

Based on the know-how gained from CCS demonstration project together with extensive R&D activities and commercial plant experiences, MHI isextensive R&D activities and commercial plant experiences, MHI is constructing the world largest CO2 capture plant in Houston, Texas for NRG Energy Inc. and JX Nippon Oil & Gas Exploration Corporation.

MHI continues extensive effort to enhance competitiveness in terms of CO2capturing cost and to accelerates commercial viability of CCS/EOR project

28CONFIDENTIAL© 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

MHI’s Technology for Future

CO2 Recovery (CDR) Plant –IFFCO Phulpur Unit (India)

CO2 Recovery (CDR) Plant –IFFCO Aonla Unit (India)

MHI’s CarbonCarbon Capture

Technology

EPC Experience

Optimization

Experience for Large

Scale

??????Optimization

CostSystem

CO

y

29

CO2 ppm


Thank you!Thank you!Thank you!Thank you!For more information please contact:p

Jerrad Thomas* – Southern Company Services, Inc.Project Manager for Plant Barry CCS/HES Demonstrationj g y

Email: [email protected]: +1-205-257-2425

*Remarks:

Takashi Kamijo – Mitsubishi Heavy Industries, Ltd.Project Manager & CO Capture Chief Engineer

Contact point for Southern Company related projects only

Project Manager & CO2 Capture Chief EngineerEmail: [email protected]

Tel: +81-45-200-9133


update of the deployment of the km cdr process€¦ · update of the deployment of the km cdr...

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