The New Sulzer Mellapak™CC™ and AYPlus™DC · PDF fileStructured Packings for...

Sulzer Chemtech

The New Sulzer Mellapak™CC™ and AYPlus™DC Structured Packings for Post-Combustion Capture

Dr. Abhilash Menon | 1st Post Combustion Capture Conference, 17 – 19 May, Abu Dhabi, UAE

1st Post Combustion Capture Conference, 17 – 19 May, Abu Dhabi, UAE| slide 2

Sulzer ChemtechSulzer Services - CO2 Capture

CO2 Absorption knowhow

Support in Process modelling

Support of Maldistribution analysis

CFD modelling

Pilot facilities

Selection of right mass transfer technology

Engineering of large size column internals

Installation services

Current focus on Process Intensification

development of next generation mass transfer technology for post-combustion capture (Mellapak™CC™ and AYPlus™ DC structured packing)

optimizing the logistics, supply-chain, fabrication and installation


Sulzer ChemtechReferences – CCS Post Combustion

Sulzer is working very closely with all major Process Licensors at the grassroot level

Pilot Plants : 19

Demo Plants : 1

Semi-Full-Scale plant : 1

Year Country Column geometry

Product

2006 Australia Circular Random packing2007 USA Circular Plastic Structured Packing2007 Norway Circular Metal Structured Packing2007 Norway Circular Metal Structured Packing2008 Sweden Circular Plastic Structured Packing2008 Germany Circular Metal Structured Packing2008 Norway Circular Metal Structured Packing2008 Denmark Circular Metal Structured Packing2009 Australia Circular Metal Structured Packing2009 Italy Circular Metal Structured Packing2009 Sweden Circular Plastic Structured Packing2009 Netherlands Circular Metal Structured Packing2009 Germany Circular Metal Structured Packing2009 Spain Circular Metal Structured Packing2009 UK Circular Metal Structured Packing2010 Germany Circular Metal Structured Packing2010 Norway Rectangular Plastic Structured Packing2010 Sweden Circular Metal Structured Packing2010 France Circular Metal Structured Packing2010 Canada Rectangular Metal Structured Packing2011 Germany Circular Metal Structured Packing


Sulzer ChemtechTypical CO2 Absorber Design

CO2 absorption

Several sections (typical 2 to 3)

Packing height: 12 to 30 m

Pump around section with cooler

Water balance

Solvent absorption

Emissions control

Minimizing solvent emissions

Vapour distribution

CFD analysis required


Sulzer ChemtechWhy Sulzer Mellapak instead of Random Packing ?

Mellapak Structured Packing offers better hydraulic & mass transfer characteristics compared to Random Packing (Rings) on a volume basis

Improved mass transfer due to increased specific area less packing height

Less pressure drop due to the defined geometrical structure less operating costs

Less weight due to the mechanically more stable structure less investment costs

* Menon, A., et.al.(2009). Post-combustion capture of CO2 (case study of a generic amine-based absorption process), Petroleum Technology Quarterly, Quarter 2' 2009, pg. 115-121


Sulzer ChemtechPressure Drop – OPEX savings

Electrical power for Flue Gas Blower to overcome pressure drop

Assumptions for pressure drop calculation

Relative efficiencies of structured against random packingMellapak 250.Y and 1” Rings have same efficiencies; 2” Ring 65% of 1” Ring

Superficial gas velocity: 1.6 m/s F-factor=1.8 Pa0.5

Specific liquid load: 30 m3/m2h

Pressure DropMellapak

1” Ring 2” Ring M250.Y

Packed height: 20 30 20 m∆p/∆z > 3 1.9 1 mbar/m∆pAbsorber > 60 57 20 mbar


Sulzer ChemtechPressure Drop – OPEX savings in CO2 Absorber

800 MW coal-fired power plant

G = 3’000’000 m3/h

Fan efficiency = 0.75

Operating time = 8’400 h/y

kWhel = 5 cents Euro

Electricity Cost for Flue Gas Fan

1” Ring: ∆pAbsorber > 60 mbar > 2’800’000.- € / year

2” Ring: ∆pAbsorber = 57 mbar 2’660’000.- € / year

M250.Y: ∆pAbsorber = 20 mbar 935’000.- € / year

Annual savings with M250.Y: 1’725’000.- € / year

Savings with M250.Y over life-span (30 y): 52’000’000 €


Sulzer ChemtechSulzer Mellapak™CC™ : Packing for CO2 Capture

Test System for Post Combustion CO2 Capture

Low partial pressure for CO2 in flue gases with atmospheric pressure

Physical solvents not applicable

Chemical solvents undergoing a reversible reaction are feasible

NaOH – CO2 system was chosen as test system for optimization of Mellapak structured packing

For most chemical solvents

mass transfer resistance : liquid-side controlled

reaction regime: fast-reaction regime

System NaOH – CO2 offers these features

The relative benefit gained from the new Sulzer MellapakCC packing compared with the conventional Mellapak packing will also be applicable to any system that belongs to the fast-reaction regime

L

total

GOG kE

pH

kk ⋅+=

/11

Define the test system for CO2 Capture

Define the benchmark packing for optimization


Sulzer ChemtechBenchmark Structured Packing for Optimization

Mellapak 250.Y is most commonly used structured packing

Mellapak 250.Y is often used as benchmark

data available in public literature

Benchmark packing for NaOH-CO2 : Mellapak 250.Y

Sulzer MellapakCC structured packing

Specifically developed for post-combustion capture application

Desired Targets

– lower pressure drop

– better or similar separation efficiency

Specifics studied : micro structure, hole size, number of holes, angle of corrugation


Sulzer ChemtechMass Transfer Performance of MellapakCC

Effective Interfacial Area (Separation Efficiency)

150

175

200

225

250

275

0 10 20 30 40 50 60

Liquid Load [m3/(m2h)]

a I [m

2 /m3 ]

MellapakCC Mellapak 250.Y Mellapak 2X

Test System: Air/NaOH-CO2

F-factor: 1.5 Pa0.5


Sulzer Chemtech

Pressure Drop Comparison MellapakCC vs. Mellapak 250.Y

0.0

0.5

1.0

1.5

0.0 0.5 1.0 1.5 2.0 2.5 3.0F-factor [Pa0.5]

∆p

/ ∆z

[mba

r/m]

0

0.5

1

1.5

Mellapak 250.Y: 0 m3/m2h



System: Water-AirColumn ID: 1 mPacking height: 3 m

C

Mellapak 250.Y - Benchmark


Sulzer Chemtech


0.0

0.5

1.0

1.5

0.0 0.5 1.0 1.5 2.0 2.5 3.0F-factor [Pa0.5]

∆p

/ ∆z

[mba

r/m]

0

0.5

1

1.5

MellapakCC: 0 m3/m2h





C

MellapakCC vs Mellapak 250.Y


Sulzer Chemtech


0.0

0.5

1.0

1.5

0.0 0.5 1.0 1.5 2.0 2.5 3.0F-factor [Pa0.5]

∆p

/ ∆z

[mba

r/m]

0

0.5

1

1.5







C



Sulzer Chemtech


0.0

0.5

1.0

1.5

0.0 0.5 1.0 1.5 2.0 2.5 3.0F-factor [Pa0.5]

∆p

/ ∆z

[mba

r/m]

0

0.5

1

1.5








C


60% lower


Sulzer Chemtech

Pressure Drop Comparison MellapakCC vs. Mellapak 2X

0

0.5

1

1.5

0 0.5 1 1.5 2 2.5 3F-factor [Pa0.5]

∆p

/ ∆z

[mba

r/m

]

MellapakCC

Mellapak 2X

Test System: Air/WaterColumn ID: 1 mPacking Height: 3 mLiquid Load: 25 m3/m2h

MellapakCC vs Mellapak 2X

20% lower


Sulzer ChemtechSulzer Mellapak™CC™: the Packing of Choice


same efficiency

and

up to 60% reduced pressure drop !

MellapakCC vs Mellapak 2X

20% higher efficiency !

and

up to 20% reduced pressure drop !


Sulzer ChemtechOPEX Savings with MellapakCC

Example for a 800 MW coal-fired power plant: MellapakCC vs. M250.Y

Assumptions

Flue gas rate = 3’000’000 m3/h

Packing height = 20m

F-factor = 1.8 Pa0.5

Avoided pressure drop with MellapakCC-3 = 10 to 12 mbar

Operating life-span for the power plant = 30 years

Avoided OPEX over life span : € 16’000’000


Sulzer Chemtech

Direct ContactCooler

Flue Gas(to atmosphere)

Absorbermake-up

water

Regenerator

CO2(to compressor)

RichSolvent

Condensate

Flue Gas(from FGD)

Flue gas blower

Lean

Sol

vent

Solvent Emissions : Showstopper for CCS ??

Recently, emission issues in post combustion CCS gained significant interest

Solvent emissions due to low vapor pressure

Nitrosamines formation (secondary amines)

Degradation products

Ammonia emissions

This could be even a “show stopper”

Environmental regulations in Europe target : Ultra low emissions


Sulzer ChemtechStandard Design Configuration (sub-ppm levels)

“Pump around” above absorption section

Water condensation (balance)

Reduced solvent emissions (low ppm range)

Solvent concentration limited by equilibrium

Excessive packing height does not result in reduced solvent emissions

2nd pump around section reduces solvent emissions to sub-ppm level

Make-up

Vfrom_Abs

Vto atmosphere

Lto_ABS

Lin_PA

Lout_PA

Pump around

Make-up

Vfrom_Abs

Vfrom 1st_PA

Lto_ABS

Lin_PA

Lout_PA

Lin_PA

Lout_PA

Vto atmosphere

1st Pump around

2nd Pump around


Sulzer ChemtechSulzer Zero Emissions Package - ‘ppb’ levels

New possible configuration

“Once through” absorption section

Water make-up flow rate typically results in 50 to 200 lt /(m2.h)

Problem: Poor wetting of packing surface reducespacking efficiency

Sulzer Zero Emissions Package

AYPlus™DC developed for these challenging very low (aqueous) flow rates

AYPlus™DC shows excellent wetting with aqueous media

A liquid distributor for extremely low flow rates was also developed : Sulzer VEPK

VEPK

Make-up

Vfrom_Abs

Vfrom PA

Lto_ABS

Lin_PA

Lout_PA

Vto atmosphere

Pump around

AYPlus DConce throughAYPlus DC


Sulzer Chemtech

AYPlus™ DC - Efficiency for Absorption SystemsTest system: DMF absorption with water

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 0.1 0.2 0.3 0.4 0.5 0.6

Liquid Load [m3/(m2h)]

HT

UO

G [m

]

F-factor: 1 to 3.5 Pa0.5

L/G / m: 2 to 40

AYPlus™DC : Efficiency Data Comparison

Mellapak M250.Y

AYPlus DC

DMF MEAFormula C3H7NO C2H7NOMW 73.1 61NBP [°C] 152 170p° (T=40°C) [mbar] 13 1.6


Sulzer ChemtechLiquid Distributor for AYPlus DC : VEPK


Sulzer ChemtechSulzer Zero Emissions Package

Absorption of .....

nitrosamines

aldehydes

other degradation products

.... has not been investigated!

Ammonia emissions cannot be reduced with such low water flow rates

AYPlus DC + VEPK Package allows to target “zero solvent emissions” forwater soluble solvents with boiling point > 150°C


Sulzer ChemtechPROCESS INTENSIFICATION

Sulzer Mellapak™CC™ for Post-Combustion CO2 Capture

Significant reduction in pressure drop

Significant improvement in separation performance

Lower OPEX and CAPEX

OPEX savings : € 16’000’000

Sulzer AYPlus™ DC + VEPK Package for Emission Avoidance at Top of CO2Absorber

Extraordinary wetting characteristics with aqueous media at extremely low liquid loads

Sulzer VEPK liquid distributor developed for extremely low liquid loads

AYPlus™ DC structured packing and VEPK liquid distributor together

– drastically increases the separation performance

– making it possible to realize ' close to zero ' solvent emissions at the top of the CO2 absorber

Sulzer Chemtech

Thank You !

Your Partner in Capturing CO2nvenient Truths


Sulzer Chemtech2-film modelThe absorption of CO2 with chemical

solvents consists of the following steps

mass transfer of CO2 in the vapour phase through the film to the interfacial area

mass transfer across the interface (however, no resistance to mass transfer assumed)

mass transfer of the physically dissolved CO2 in the liquid phase from the interface into the bulk of the liquid phase

reaction of the CO2 with the solvent (e.g. amine) in film and bulk of the liquid phase


Sulzer ChemtechChemical Absorption

Reaction Regimes (irreversible, pseudo first order)

I : slow Hold-up determines liquid side mass transfer A bubble column might be preferably used (not relevant in CCS)

II : intermediate kL and aI determine liquid side mass transfer Packings or Trays might be preferably used

III : fast aI determines liquid side mass transfer Structured packing is preferably used

IV : instantaneous kL and aI determine liquid side mass transfer(these systems tend to be vapor side controlled) Packings might be preferred

reaction is…..


Sulzer ChemtechPacking Technology

Mellapak® Structured packing

MellapakPlus ® Structured packing

Nutter Ring I-Ring P-RingC-Ring

Random packings

Packing Type Geometrical area

(m2/m3)

M252Y 250 C-Ring 1" 250 C-Ring 1.5" 187 I-Ring 25 226 I-Ring 40 151


Sulzer ChemtechMellapakPlus

MellapakPlus – Proven latest generation of Structured Packings : up to 40% more capacity

The hold-up profile of Mellapak above the intersectional loading point isreduced by the smooth change of flow direction achieved by the newMellapakPlus structure. This suppresses the local flooding at intersectionpoints and increases the overall packing capacity.

Mellapakpackingelements

Mellapak MellapakPlusHold-up aboveintersectionalloading point typical for Mellapak


Sulzer Chemtech

Holdup Profile

Bottleneck Evaluation

Flooding of Mellapak


Sulzer ChemtechFlooding of MellapakPlus

Bottleneck Evaluation

Holdup Profile


Sulzer ChemtechSize is a Challenge

Typical Values of 800 MWel Coal Based Power Station

Flue gas rate: 3’000’000 m3/h

CO2 concentration: 14 Vol-%

CO2 capture per year: 6 Mt/y

Resulting Absorber Size

Assumed superficial gas velocity: 1.6 m/s (F-factor = 1.8 Pa0.5)

Required cross sectional area: 500 m2 2 x 250 m2

Absorber diameter

Rectangular : 2 trains each 12 m x 21 m

Square : 2 trains each 15.8 m x 15.8 m

Circular : 2 trains each 17.8 m


Sulzer ChemtechTest System for Post-Combustion Absorbers

Reaction Regimes (irreversible, pseudo first order)

I : slow Hold-up determines liquid side mass transfer A bubble column might be preferably used (not relevant in CCS)

II : intermediate kL and aI determine liquid side mass transfer Packings or Trays might be used

III : fast aI determines liquid side mass transfer Structured packing is preferably used

IV : instantaneous kL and aI determine liquid side mass transfer(these systems tend to be vapor side controlled) Packings might be preferred

reaction is….. E.U. Schlünder: Einführung in die Stoffübertragung

IVo

post-combustion CCS

packing surface

bulk liquid

laminar liquid film


Sulzer ChemtechMellapak 250.Y - Benchmark

Measured Effective Interfacial AreaMellapak M250.Y

100

120

140

160

180

200

220

240

260

280

0 10 20 30 40 50 60 70

Specific liquid rate [m3/m2h]

Mea

sure

d in

terf

acia

l are

a [m

2 /m3 ]

Tsai et al.WeimerSulzer

Test system: NaOH-CO2

The New Sulzer Mellapak™CC™ and AYPlus™DC · PDF fileStructured Packings for...

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