CCS Options & Cost Reductions with New
UOP SELEXOLTM Process Flow Schemes
Rajj Palla
UOP LLC, A Honeywell Company
Gasification Technology Conference
October 31stt – November 3rdd, 2010
Washington, DC
UOP 5491-01
© 2010 UOP LLC. All rights reserved.
Advantages of
Enhanced Selexol Flowscheme
y Meet emission requirements
q when venting g of
CO2 is required
y Meet CO2 purity for Urea Production (less than
100 ppmv)
y Recover valuable H2 and CO
y No separate thermal oxidation is required
With Little/No Increase
in Overall Processing g Costs
UOP 5491-02
CO2 Purity Specifications Widely Vary.......
CO2 Pipeline Example:
Purpose Kinder Morgan
y Transportation/Storage
p g CO2 > 95 %
y Enhanced Oil Recovery HC's <5%
N2 <4%
y Urea Production
H 2S < 20 ppmv
Operational flexibility O2 < 10 ppmw
y Emergency venting H 2O < 30 lbs/MMCF
UOP 5491-03
CO2 Purity Specifications Widely Vary.......
Examples of CO2 in
Purpose Enhanced Oil Recovery
y Transportation/Storage
p g Canyon Reef Weyburn
y Enhanced Oil Recovery CO2 > 95 % > 96 %
HC's <4% <3%
y Urea Production
H2, N2, CO <4% < 0.1%
Operational flexibility H2S < 1500 ppmv < 0.9 %
y Emergency venting H2O < 28 lbs/MMCF
Typical
T i l CO2 Purity
P it Spec
S
for Urea Production:
To Urea
CO2 >99.5 mol%
H2 <0.3 mol%
N2 <0.1 mol%
CO <0.06 mol%
H2S <0.1 ppmv
UOP 5491-04
CO in CO2 Stream is a Controlled
Substance....
Purpose
y Transportation
p
y Enhanced Oil Recovery
y Urea Production
y Storage
Operational flexibility
y Venting:
g Start / Stop
p / Emergency
g y
Example: US Permitting Limit for Point Sources of CO:
Typical purities from AGR Permissible Days of Venting
CO2 Purity CO in CO2 Minor Source Major Source
95% 2% 1.1 2.5-4.5
99% 0.2% 9 22-45
99% 0 1%
0.1% 18 44-90
99.8% 100 ppmv 180 Continuous
UOP 5491-05
Natural Gas – Initial Flow Scheme
Treated Gas
3 mol%CO2
CO2
Absorber UOP MOLSIVTM
Dehydration CO2 Compression
EOR
Natural Gas CO2
65 mol% CO2
y Natural Gas - High CO2 Content y Capex
– 400 MMSCFD = 20,000 kmol/h – Selexol Unit
– 80 bar – CO2 Compression
– 35 mol%
l% methane,
th h
heavier
i hydrocarbons
h d b
& nitrogen
– 65 mol% CO2
y Treated Gas
– Pipeline specification: 3 mol% CO2
y EOR = Enhanced Oil Recovery
– CO2 Pressure: 130 bar UOP 5491-06
Natural Gas
– Final Flow Scheme
Treated Gas
3 mol%CO2
UOP MOLSIVTM Dual Refrigerant
Dehydration CO2 Fractionation
CO2
Absorber
Natural
Gas CO2
65 mol%
CO2
Li id HC
Liquid CO2
EOR - 130 bar
y Dual Refrigerant CO2 Fractionation (DRCF)
– Chilling
g of natural gas
g stream
– Bulk Removal of CO2
y UOP MOLSIV Dehydration
– Fixed bed adsorption – thermal regeneration
– Avoid freezing of H2O in DRCF
y UOP Selexol Process
– Trim CO2 Removal UOP 5491-07
Benefits of Selexol + DRCF
Flowscheme
Rotating Equipment Power Required
By Process Unit (MW)
Compression Pumping
Plant Process Option CO2 Frac. SELEXOL CO2 Frac. SELEXOL Total
Conventional SELEXOL -- 71.3 -- 10.6 81.9
Dual Refrig.
Refrig CO2 Frac +
SELEXOL 11.5 26.1 5.0 2.9 45.5
y Savings:
– OPEX : US$ 30- 40 MM
– CAPEX : US$ 39 MM
– Hydrocarbon losses : - 75%
UOP 5491-08
Can this Concept
be Applied in Gasification?
T i l Gasification
Typical G ifi ti Complex
C l y CO in the CO2 stream is <100 ppmv
y CO2 purity as high as 99.7 mol%
y Sulfur in treated gas as low as
Typical Raw Syngas 0.1 ppmv
y H2 30 - 50% y Sulfur in CO2 as low as 2 pp
ppmv
y CO y Adjustable acid gas composition
30 - 50% Subject CO2
y Ar 0.5 - 1%
y N2 0.7 - 1.5%
of this
y CO2 5 - 19% Study
y H2S 0.5 - 2% CO2
y COS 200-1000 ppmv Compression
y Ni & Fe Carbonyls
y HCN, NH3 ...
Coal or
PetCoke, Raw Treated
Biomass Syngas Sour Selexol Syngas
Gasifier Shift U it
Unit
Applications:
O2 Tail H2S
Gas y Power
y Chemicals
Sulfur Sulfur y Hydrogen
Air
Separation Recovery y Liquid Fuels
UOP 5491-09
Selexol Flow Schemes - Gasification
Sulfur Removal & CO2 Capture—Conventional
Treated
Gas
y CO in the CO2 stream is ~500 ppmv
y CO2 purity as high as 99.7 mol%
y Sulfur in treated gas as low as
CO2
0.1 ppmv
Absorber y Sulfur in CO2 as low as 2 ppmv
y Adjustable acid gas composition
CO2 Acid
S i
Stripper Gas
Lean Solution Reflux
Filter Accumulator
Sulfur Makeup
Absorber Water
Reflux
Feed H2S Pump
Export
Gas Concentrator Water
Stripper
Reboiler
Packinox
Exchanger
UOP 5491-10
Selexol Flow Schemes - Gasification
Sulfur Removal & CO2 Capture – Conventional
y Syngas Feed Flow: 409 MMSCFD
y Equipment Costs : BASE
y Feed Syngas Pressure: 629 psig
y CAPEX : BASE
y Feed: CO2: 41.15 mol% and H2S: 0.86 mole%
y OPEX : BASE
y CO2 Product: 2.91 MM Tons
y CO2 Pressure: 2200 psia
y CO Recovery: 99.05%
BASE Case Unit Specification Simulated Value
Total Sulfur in Treated Gas ppmv <1 0.10
Total CO2 in Treated Gas mol% <3.5 3.3
CO2 Purity mol% >99.5 99.5
Total CO2 Recovery mol% 90 92
Total Sulfur ((dry)
y) in Combined CO2 Product ppmv
pp <10 7.8
CO (dry) in Combined CO2 Product ppmv <500 431
H2S (dry) in Acid Gas to SRU mol% >30 38
UOP 5491-11
Integration of Selexol Process
and Upstream DRCF
Treated
Gas y CO in the CO2 stream is
CO2 ~10 ppmv
y Minimum CO2 purity as high
as 99.5 mol%
UOP MOLSIVTM Dual Refrigerant
g CO2
Dehydration CO2 Fractionation Absorber y Sulfur
S lf ini treated
t t d gas as low
l
as 0.1 ppmv
y Sulfur in CO2 as low as 2
ppmv
y Adjustable acid gas
composition
Sulfur
y Dual Refrigerant CO2 Fractionation Absorber
– Bulk Removal of CO2 Feed
Gas
y UOP MOLSIV Dehydration Sulfur Concentration
and Regeneration
– Fixed bed adsorption – thermal Acid
regeneration Gas
– Avoid freezing of H2O in DRCF
y UOP Selexol Process
– Trim CO2 Removal UOP 5491-12
Integration of Selexol Process
and Upstream DRCF
y Syngas Feed Flow: 409 MMSCFD
y Feed Syngas Pressure: 632 psig y Equipment Costs : BASE x 0.93
y Feed: CO2:41.15 mol% and H2S: 0.86 mole% y CAPEX : BASE x 1.37
y CO2 Product: 3.01 MM Tons y OPEX : BASE x 1.20
y CO2 Pressure: 2200 psia
y CO Recovery: 99.92%
Future Gen Ortloff Syngas Frac Case HP
wo CO2 Flash Unit Specification Simulated Value
Total Sulfur in Treated Gas ppmv <1 0.01
Total CO2 in Treated Gas mol% <3.5 3.49
CO2 Purity mol% >99.5 99.56
Total CO2 Recovery mol% 90 91.68
Total Sulfur (dry) in Combined CO2 Product ppmv <10 4.00
CO (dry) in Combined CO2 Product ppmv <100 39.30
H2S (dry) in Acid Gas to SRU mol% 30% 38.28
UOP 5491-13
Integration of Selexol Process
and Downstream DRCF
H2 and CO Treated
Gas
UOP MOLSIVTM Dual Refrigerant
Dehydration CO2 Fractionation
CO2
Absorber
CO2 CO2
Liquid HC CO2
Sulfur
Ab
Absorber
b
Feed
Gas Sulfur Concentration
and Regeneration
Acid
Gas
UOP 5491-14
Integration of Selexol Process
and Downstream DRCF
y Syngas Feed Flow: 409 MMSCFD
y Feed Syngas Pressure: 632 psig y Equipment Costs : BASE x 1.03
y Feed: CO2:41.15 mol% and H2S: 0.86 mole% y CAPEX : BASE x 1.09
y CO2 Product: 3.01 MM Tons y OPEX : BASE x 0.98
y CO2 Pressure: 2200 psia
y CO Recovery: 99.70%
F t
Future Gen
G Ortloff
O tl ff Syngas
S Frac
F Case
C HP
wo CO2 Flash Unit Specification Simulated Value
Total Sulfur in Treated Gas ppmv <1 0.01
Total CO2 in Treated Gas mol% <3.5 3.49
CO2 Purity mol% >99.5 99.6
Total CO2 Recovery mol% 90 92
Total Sulfur (dry) in Combined CO2 Product ppmv <10 4 00
4.00
CO (dry) in Combined CO2 Product ppmv <100 39
H2S (dry) in Acid Gas to SRU mol% 30% 39
With Little/No Additional Cost
for this Flowscheme UOP 5491-15
Comparison with Conventional Scheme
y “Conventional Scheme” vs Selexol Process + DRCF
Selexol Process +
C
Conventional
ti l Scheme
S h
DRCF
CO2 Purity > 99.5 mol% CO2 > 99.5 mol% CO2
< 500 ppmv CO < 50 ppmv CO
<400
400 ppmv H2 < 50 ppmv H2
H2 Recovery 99.7 99.9
CO Recovery 99.0 99.7
Op Cost Base 0.98% x Base
SELEXOL Unit Base 2 Flash Drums removed
Equipment 1 Compressor removed
CapEx Base 1.09 x Base
CO2 Compression Conventional DRCF Scheme
UOP 5491-16
Conclusions
y Selexol + DRCF can easily meet CO2 purity specification
with little/no additional cost for this flowscheme
– Meet emission requirements when venting of CO2
is required
– Recover valuable H2 and CO
– No
N separate t th
thermall oxidation
id ti is
i required
i d
y Different applications have different purity standards
– Designing for unnecessary stringent purity levels adds
unnecessary cost to the plant
UOP 5491-17
“The information in this presentation should not be construed as a representation for which UOP assumes legal responsibility,
or an authorization or recommendation to practice a patented invention without a license.”
UOP 5491-18
