Publications Database - List of capture publications

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    June, 2005

Vol 1 Chapter 14: Coke gasification: advanced technology for separation and capture of CO₂ from gasifier process producing electrical power, steam and hydrogen

Martin Holysh, Suncor Energy Inc, Canada

Abstract: The CO₂ Capture Project (CCP) was established by eight leading energy companies to develop novel technologies that significantly reduce the cost of capturing CO₂ for long-term storage. A significant focus of the project was in the area of pre-combustion technologies for the removal and capture of carbon dioxide (CO₂) prior to fuel combustion.

This advanced technology study builds on previous CCP work that developed a conceptual process and engineering design for an integrated gasification combined cycle (IGCC) plant using petroleum coke as the feedstock to produce electrical power, steam, and hydrogen. Conventional absorption technology using the physical solvent Selexol was utilized for CO₂ removal and capture.

The subject of this study was the development of a conceptual process and engineering design of an IGCC plant using petroleum coke as the feedstock to produce electrical power, steam, and hydrogen utilizing Fluor’s CO₂LDSep^SM advanced technology for CO₂ removal and capture.

The study concludes that CO₂LDSep^SM technology can reduce the cost of CO₂ capture by 16% when compared to the use of conventional Selexol technology. Neither the Selexol nor CO₂LDSep^SM technologies result in increased NO_x or SO_x emissions as compared to a baseline case with no CO₂ capture.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(158 Kb)      View   Download

    June, 2005

Vol 1 Chapter 13: Development of the sorption enhanced water gas shift process

Rodney J. Allam et al, Air Products plc, UK

Abstract: The CO₂ Capture Project (CCP), working with Air Products and Chemicals and with funding support of the US DOE, has undertaken development of a novel precombustion decarbonization technology referred to as the sorption enhanced water gas shift (SEWGS) process. This technology is particularly attractive for decarbonizing gas turbine fuel, and hence provides opportunities for power generation with minimal CO₂ emissions, high power efficiency and potentially lower cost of capturing CO₂ for storage.

The SEWGS process simultaneously converts syngas containing CO into H₂ and CO₂ and removes the CO₂ from the product hydrogen by adsorption. The system operates as a multi-bed pressure swing adsorption unit, with each bed packed with a mixture of shift catalyst and a high-temperature CO₂ adsorbent. Carbon in the feed gas in the form of CO and CO₂ are removed from the product gas by the CO₂ adsorbent, and after specific PSA process steps, rejected as relatively high-purity CO₂ for recovery. The product hydrogen produced during the feed step contains the excess steam from the reaction and any nitrogen from the syngas generation, and is at high temperature and feed pressure. This hot fuel mixture can be burned in gas turbines with higher turbine efficiency than with natural gas firing and substantially lower NO_x formation.

During a 2-year development program, the key process performance and design issues were studied through a combination of experimental work, simulation and techno-economic evaluation. The experimental program developed and characterized candidate adsorbents in a range of tests including thermogravimetric analysis and the use of a cyclic process test unit. Many potential CO₂ adsorbent materials were screened prior to identification of the leading material, a promoted hydrotalcite (HTC), which showed the highest cyclic capacity for removal of CO₂ under the conditions of interest. Detailed parametric studies were conducted with this material to provide the sizing data for design of full-scale SEWGS units. Proof-of-concept test runs were conducted in the process test unit with a model syngas feed containing CO, H₂ and CO₂, which was fed in breakthrough and cyclic modes to a single bed vessel containing a mixture of catalyst and HTC. These tests demonstrated that the equilibrium limit for conventional reactors was overcome, a substantially decarbonized hydrogen product was produced, and a carbon recovery of over 80% was achieved.

Process designs were developed by APCI for two CCP case studies, a 400 MW combined cycle case and capture from multiple gas turbine drives in an oil-field gas compression system. Flow schemes were developed using autothermal reforming to produce syngas from the natural gas feed. Air blown and oxygen blown autothermal reformer schemes were prepared and overall power generation process performance was determined by ASPEN simulation. Process equipment sizing calculations and SEWGS cost estimates were conducted and passed, along with utility requirements, to CCP-funded cost estimators. The CCP common economic model was used to determine costs of CO₂ capture for the process in each case study and compared with the existing baseline technologies.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(1102 Kb)      View   Download

    June, 2005

Vol 1 Chapter 9: Self-assembled nanoporous materials for CO₂ capture
Part 2: Experimental studies

Ripudaman Malhotra et al, Chemical Science and Technology Laboratory, SRI International, USA

Abstract: Adsorption tests verified the expected high capacity of copper terephthalate complex for adsorbing CO₂. The CO₂ isotherm did not level off up to CO₂ partial pressures of 25 psig. The selectivity of the material for CO₂ over N₂ is about 8. Analogous tests with a silicalite (Hisiv 3000) showed saturation behavior above CO₂ partial pressures of 10 psig. Based on laboratory measurements and simulations, a PSA process was designed to capture the CO₂ from a 400 MW gas-fired power plant that would meet the specifications of 90% capture and 96% CO₂ purity. Because pressurizing the total plant exhaust (1586.1 MMSCFD) would place a very high parasitic load (about 260 MW), we opted for a design in which the beds are charged at the pressure of the exhaust, and the CO₂ product is recovered by pulling vacuum. The highest purity obtained in the experiments was 67.9% CO₂ with 34.1% recovery. The production rate was 0.0113 sL/min. Additional simulations of the PSA process revealed that CO₂-rich product with 97% purity is achievable by a 2-bed/5-step PSA process using the copper terephthalate adsorbent; however, it would require a long rinse (with part of the CO₂-rich stream) and purging at low absolute pressure to obtain a high-purity CO₂-rich product.

A rough economic analysis, accounting for capital and power consumption of the PSA system, gave estimated costs, per ton of CO₂ captured, of $406 for the powdered copper terephthalate adsorbent, $495 for the granulated material, and $393 for UOP Hisiv 3000. Considering that the former adsorbents were experimentally obtained from batch syntheses and were not optimized, it is likely that they show good potential for this application, relative to the existing commercial product.

The most striking result though was that the power requirements for CO₂ capture are enormous, about 1 GW or more than twice that of the power plant for which this capture system was being designed. It did not matter whether the adsorbent was copper terephthalate or Hisiv 3000, although it should be pointed out that under the operating conditions, the benefits of the large capacity of copper terephthalate were not being realized. In any case, in order to meet the stipulated requirements, the adsorbent for a PSA-based system must be able to deliver about two orders of magnitude better performance. That goal seems unlikely, and other scenarios in which some of the constraints are relaxed should also be considered.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(374 Kb)      View   Download

    June, 2005

Vol 1 Chapter 9: Self-assembled nanoporous materials for CO₂ capture
Part 1: Theoretical considerations

Ripudaman Malhotra et al, Physical Sciences Division, SRI International, USA

Abstract: Nanoporous materials have been shown to have very high adsorption capacities for gases. We examined their potential application in a PSA system to capture CO₂. Of particular interest to us was the range of selfassembled materials that could be generated from copper dicarboxylate systems. These salts have a square lattice whose cells could be tailored to accommodate multiple molecules of CO₂ and thereby optimize the material for maximum adsorption capacity. With multiple CO₂ molecules being adsorbed in each cell there is also the possibility that the system would display cooperative behavior. We describe here the thermodynamics of these systems and show that a significantly larger amount of an adsorbate species can be shifted between the vapor and adsorbed states for a given pressure swing. To further assess the potential benefits of using such materials, we simulated the breakthrough behavior of CO₂ from a packed bed containing activated carbon and copper terephthalate. These simulations show that for a given bed diameter, the appropriate bed length would be about a third that for carbon alone, even if copper terephthalate displayed no cooperativity. The bed length could be further reduced to a quarter if there were even a modest degree of cooperative binding.

Carbon Dioxide Capture for Storage in Deep Geologic Formations - Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(359 Kb)      View   Download

    June, 2005

Vol 1 Chapter 32: Cost and feasibility study on the Praxair advanced boiler for the CO₂ Capture Project's refinery scenario

Leonard Switzer et al, Praxair Inc, USA

Abstract: Praxair Inc has developed a preliminary design and cost estimate for a boiler system that uses Praxair's advanced boiler technology to produce product steam, a system to capture the CO₂ from the boiler exhaust. This report is in response to the Carbon Capture Project's refinery scenario. A model has been developed for an advanced boiler that combusts a gaseous fuel with O₂, which is supplied from a thermally integrated network of oxygen transport membranes (OTMs). The exhaust from this system - being primarily CO₂ and water -is then purified and compressed to recover the CO₂ as a product. The OTMs are in the form of tubes arranged perpendicular to the direction of the exhaust gas flow in the furnace. Air circulated inside the membranes provides oxygen for combustion. As O₂ is transported through the membrane, it combusts with the fuel and creates the required oxygen partial pressure gradient through the tube wall to facilitate transport. The heat release from the combustion keeps the OTMs at the required temperature for operation as well. Thus, the O₂ separation system is thermally and chemically integrated with the combustion system. Based on the economic analysis conducted to date, a boiler with integrated ceramic membranes has the potential for substantial capital and operating cost savings when CO₂ capture is required. In the case of a more conventional boiler without CO₂ capture, the energy savings can potentially pay for the incremental cost of the OTM boiler in ~2 years.

Carbon Dioxide Capture for Storage in Deep Geologic Formations - Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(563 Kb)      View   Download

    June, 2005

Vol 1 Chapter 8: Removal of CO₂ from low pressure flue gas streams using carbon fibre composite molecular sieves and electric swing adsorption

Paul Hurst, BP plc, UK

Abstract: A novel separation technology based on electric potential field desorption of CO₂ from a carbon fibre composite adsorbent was proposed by the Carbon Materials Technology Group at Oak Ridge National Laboratory. This paper, Removal of CO₂ from low pressure flue gas streams using carbon fibre composite molecular sieves and electric swing adsorption, describes the experimental work and results from laboratory testing of the concept by the CCP Post-Combustion Technology Team. It was determined that the desorption step was controlled by surface heating of the composite adsorbent rather than a change in surface potential so originally believed. Electric power demands would make commercial application at the required scale uneconomic.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(302 Kb)      View   Download

    June, 2005

Vol 1 Chapter 4: Post-Combustion CO₂ Seperation Technology Summary

Dag Eimer

Abstract: The post-combustion technology team (the Team) found a number of interesting ways in which the cost of carbon dioxide removal could be reduced from the base case. A number of technologies have been investigated. It is the feeling of the Team that there are many good research opportunities with respect to reducing the total cost of carbon dioxide removal. Extensive studies were completed in these areas, all based on absorption:

• Base case.
• Nexant low-cost design.
• Nexant integrated low-cost design.
• Kvaerner-Mitsubishi (MHI): a new contactor combined with a new absorbent.

The Team has also evaluated:

• Better adsorbents, and the potential of adsorption processes.
• The basis for dismissal of membranes and cryogenics for this application.
• New chemical approaches, producing a few research proposals.
• Alternative equipment technologies.

Finally, the Team has defined what is referred to as best integrated technology (BIT) based on the studied absorption technologies. BIT is not ready to be built, as some features need to be checked. The BIT concept must not be seen as the ultimate post-combustion solution as there are identified research opportunities available, and more are foreseen for the future.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(116 Kb)      View   Download

    June, 2005

Vol 1 Chapter 5: CO₂ Removal from Power Plant Flue Gas - Cost Efficient Design and Integration Study

Gerald N. Choi, Robert Chu, Bruce Degen, Harvey Wen, Peter L. Richen and Daniel Chinn

Abstract: Nexant Inc., an affiliate of Bechtel Corporation, was given the task to evaluate various engineering options to reduce the costs of amine-based carbon dioxide (CO₂) capture from flue gas generated by a 400 MW natural gas fired combined cycle (NGCC) power plant. ChevronTexaco, a member of the CO₂ Capture Project (CCP), was the project manager for the study. The Nexant study consisted of three phases; Phase 1 involves technology survey and brainstorming to identify potential cost cutting ideas, and conducts tradeoff evaluations to quantify the potential cost reductions; Phase 2 consists of developing a base case CO₂ amine plant design and cost estimate for benchmarking, and implements Phase 1 ideas to develop a low-cost amine plant design as a stand-alone plant; Phase 3 consists of developing a stand-alone NGCC power plant design and cost estimate for benchmarking, and an integrated NGCC/amine plant design to explore further cost savings via process integration. A total of 64 cost cutting ideas were identified during the Phase 1 study, of which 39 were considered unfeasible to evaluate in detail due to either insufficient performance or cost data. Tradeoff studies were performed on 18 of the remaining 25 ideas with eight being selected for final development of the Phase 2 low-cost amine plant design. The remaining seven ideas are related to the Phase 3 integrated NGCC/amine plant design, and two out of the seven were selected for implementation in the final integrated design. By incorporating the eight cost cutting ideas, a low-cost amine plant design was developed at a reduced capital cost of about 40%. All of the eight cost-reduction ideas implemented are related to equipment design changes, and are deemed to be technically feasible with current commercially available equipments. Their predicted performances (either via process simulation or from vendor quotes) will need to be verified via pilot plant testing. Phase 3 integration of NGCC with the low-cost amine plant further reduced the capital cost of CO₂ removal by approximately 15% for a total cost reduction of about 55%. The integrated design incorporated ideas of reducing the gas turbine (GT) combustion air to half with flue gas recycle, and by relocating 75% of the amine reboiling duty directly into the HRSG (heat recovery steam generator) unit. These cost-reduction designs are considered technically possible. It is recommended that technology vendors to be funded for a preliminary engineering design to confirm the performance of low oxygen (~13% O2) combustion and the possibility of integrating an amine reboiler directly into a HRSG construction design.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(263 Kb)      View   Download

    June, 2005

Vol 1 Chapter 6: Post-Combustion Seperation and Capture Baseline Studies for the CCP Industrial Scenarios

Paul Hurst and Graeme Walker

Abstract: The aim of the CO₂ Capture Project is to develop new and novel technologies that significantly reduce the cost of capturing and storing CO₂. The project has three distinct elements; pre-combustion de-carbonisation, the use of oxygen-rich combustion systems and post-combustion CO₂ capture. In order to evaluate any new or novel technology, baseline studies are required that quantify the current best available technology. This report summarises two such studies for the post-combustion CO₂ capture element based on two BP-owned or part-owned operating facilities:

• The Central Gas Facility, Prudhoe Bay, Alaska—representative of CO₂ recovery from the exhaust gas of multiple simple cycle gas turbines.
• BP’s Grangemouth Complex, Scotland—representative of CO₂ recovery from multiple flue gas emissions from a refinery or petrochemical complex heaters and boilers.

The studies have been conducted by Fluor. They detail process designs and cost estimates to capture approximately 1.8–2 million tonnes of CO₂ per year and deliver the captured CO2 to the battery limits of the particular site at a pressure of 220 barg and essentially water-free.

The specific conclusions drawn from the two studies are that:

• The capture of such large amounts of CO₂ is technically feasible.
• The installed costs are very high.
• Prudhoe Bay capital cost is estimated at $1.659 billion, equivalent to $130 per tonne of emitted CO₂ avoided, and
• Grangemouth capital cost is estimated at $476 million, equivalent to $50–60 per tonne of CO₂ captured. This range relates to the anticipated variation in operating costs.

The study assesses generic issues that will be common to any retro-fit post-combustion CO₂ Capture Project, and provides a suitable baseline against which developing technologies can be evaluated.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(369 Kb)      View   Download

    June, 2005

Vol 1 Chapter 7: KPS Membrane Contactor Module Combined with Kansai/MHI Advanced Solvent, KS-1 For CO₂ Seperation from Combustion Flue Gases

Marianne Søbye Grønvold, Olav Falk-Pedersen, Nobuo Imai and Kazuo Ishida

Abstract: The Kansai Electric Power Co., Inc. (Kansai) and Mitsubishi Heavy Industries, Ltd (MHI) have developed solvents for a CO₂ capture process. One of the solvents, KS-1 was selected for this combined process with the gas/liquid membrane contactor, developed by Kvaerner Process Systems a.s. (KPS). The KPS membrane contactor and Kansai/MHI, KS-1 solvent both pose technical advantages to the current convention of CO₂ capture processes, respectively; however, the combined effect has never been determined. This test was undertaken in order to determine the extent of advantages the combined process holds over the current standard of CO₂ capture. Data was recovered for the construction of a mathematical model regarding the performance of the combined process. This data were in turn, used for the scale-up calculations for a CO₂ capture plant at a 350 MW power plant. In the second phase of the CCP project, the principle of a membrane water wash unit was tested in a smallscale laboratory unit. This was done to verify the upscale calculations done for a membrane water wash unit in the first phase of the project.

Carbon Dioxide Capture for Storage in Deep Geologic Formations – Results from the CO₂ Capture Project Capture and Separation of Carbon Dioxide from Combustion Sources - Volume 1
Edited by: David C. Thomas, Senior Technical Advisor, Advanced Resources International Inc, USA

(821 Kb)      View   Download

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