02 - R. Allen (Man Turbo) Quality Meeting for... · Integrally-geared Compressors ... Cottbus MAN Turbo AG R. W. Allen 07.09.2009 < 10 > ... HP CO2 Compressor RG 040/08 8-stage

MAN Turbo Engineering the Future – Since 1758.

COCO2 , its Contaminant’s, and their Treatment during gCompression in “OxyFuel” Applications

MAN Turbo AG R. W. Allen 07.09.2009 < >1Panel Discussion – 1st OxyFuel Conference - Cottbus

pp

Product InformationProduct Information

CO2 Compression

Process Integration

ExperienceExperience

OxyFuel Applications

2MAN Turbo AG R. W. Allen 07.09.2009 < >Panel Discussion – 1st OxyFuel Conference - Cottbus

Axial Compressors

Suction flow rates t 1 5 illi ³/hup to 1.5 million m³/h

Max. discharge pressure up to 25 barp

Fuel gas Air storage

Liquefied natural gas

Fluid catalytic cracking

Air separation

Methyl Tertiary Butyl Ether g

GTL

Blast furnace gas

y

Nitric acid

Terephthalic acid


Coal / oil gasification Flue Gas

Centrifugal Compressors

Suction flow ratest 660 000 3/hup to 660,000 m3/h

Max. discharge pressureup to 1000 bar

Refrigerationprocesses

Natural gasprocesses

Air separation

Methanol

Associated gas

Pipeline

Ammonia

Nitric acid

Oxygen

Top gas

Refinery


Nitric acid

Ethylene

Integrally-geared Compressors

Suction flow rates t 350 000 3/hup to 350,000 m3/h


Refinery /Petrochemicals

Ammonia

F lNitric acid

Syngas

Fuel gas

CO2 compression

Fluid catalyticTerephthalicacid

Steam

ycracking

Urea

Air separation


Air separation

Process Gas Screw Compressors

Suction flow ratest 100 000 ³/hup to 100,000 m³/h


Mining

Chemicals

Iron & Steel

Oil & GasOil & Gas

Petrochemicals

Dust Laden Gases


Steam Turbines

Live steamt 130 bup to 130 bar

and 570°C

Power output t 120 MWup to 120 MW

G t d iGenerator drive

Mechanical drive


Process Gas Expanders

Max. inlet pressure 65 bar

Max. inlet temperature 760°C

Power output up to 30 MW

Energy recovery for:for:

Fluid Catalytic Cracking

Top gas

Nitric acid

Terephthalic acid


Terephthalic acid

IGCC / OxyFuel


CO2 Compression

Process Integration




History

UNTIL THE MID 1990’s THERE WERE ONLY TWO

y

UNTIL THE MID 1990 s THERE WERE ONLY TWO WAYS TO COMPRESS CO2 TO ~200 bar, i.e. MULTI-STAGE RECIPROCATING COMPRESSORS OR, MULTI-CASING CENTRIFUGAL COMPRESSORS .

IT WAS AT THIS TIME THAT MAN TURBO INTRODUCED THE SINGLE BLOCK, MULTI-PINION, INTEGRALLY GEARED COMPRESSOR FOR THIS SERVICE IN A RUSSIAN UREA PLANT.

DUE TO ITS LOW POWER REQUIREMENT ANDDUE TO ITS LOW POWER REQUIREMENT, AND LOWER CAPEX, THE INTEGRALLY GEARED CO2

COMPRESSOR IS TODAY, THE STANDARD SOLUTION FOR UREA FERTILISER PLANT


APPLICATIONS.

Multi Shaft Gear Compressor for UREAp

10-stage Integrally Geared Compressor (W t CO Mi )(Wet CO2 - Mix)forUrea Synthesis

Type RG 053-10

Fl 23 500 ³/hFlow: 23 500 m³/hPressure: 1.04 bar -

200.0 barPower: 4 500 kW


T / S Diagram NOVAZOT UREA PlantCompression CharacteristicCompression Characteristic

2 0 0

P r e s s u r e p i n b a r

200

150

100

50 10 5,0

1,0 0,5

0,1

300

400

500

0,05

1 8 0

1 6 0

1 4 0

1 2 0

D

1 01 2 0

1 0 0

8 0

6 0

4 0

9

S atur

e T

in °

C

4 0

2 0

0

- 2 0

8 7 6 5 4 3 2

Tem

pera

1 ba

r

- 4 0

- 6 0

- 8 0

- 1 0 04 ,8 5 ,0 5 ,2 5 ,4 5 ,6 5 ,8 6 ,0 6 ,2 6 ,4 6 ,6 6 ,8 7 ,0

0,01


E n t r o p y s i n k J / ( k g K )4 ,8 5 ,0 5 ,2 5 ,4 5 ,6 5 ,8 6 ,0 6 ,2 6 ,4 6 ,6 6 ,8 7 ,0

High Pressure CO2 CompressorsSensitivity of Real Gas Factors for Various GasesSensitivity of Real Gas Factors for Various Gases


CO2 Data & Influence of Impurities2 p

The triple point for a CO2mixture containing 4% N2increases from 73 bar 31oC for CO2 to 82.3 bar 26.6oC

Other contaminents have similar influences, some greater than others; H2 has a major influence on the properties of the mixture!

A new handbook in preparation by the CCSa

(Carbon Capture & Storage Association) will cover these issues.


courtesy

Performance Map NOVAZOT UREA Plant10 Stage Design, IGV Control10 Stage Design, IGV Control


Calculated according to the Lee-Kessler-Plöcker (LKP) method

Integrally Geared Compressor DesignUREA Plant Applications : HP CO2 Compressor RG 040/08UREA Plant Applications : HP CO2 Compressor RG 040/08

8-stage integrally geared compressor wet CO / UREA plantwet-CO2 / UREA plant

Type RG 040-8Flow: 12 800 m³/hPressure: 1 - 160 barPower: 4 200 kW

Packaged Compressor Design on steel structure with closeon steel structure with close coupled inter-coolers for easy handling and installation.


Why Gear Type Compressors?

THE MULTI-CASING, IN-LINE, CENTRIFUGAL COMPRESSOR TRAIN HAS THE DISADVANTAGE THAT, WHEN USED ON A GAS SUCH AS CO2 , ONLY THE FIRST FEW STAGES OPERATE NEAR THEIR OPTIMUM EFFICIENCY. THIS RESULTS IN A HIGH CAPEX / HIGH OPEX SOLUTIONHIGH CAPEX / HIGH OPEX SOLUTION.

THE INTEGRALLY GEARED CENTRIFUGAL COMPRESSOR HAS THE ADVANTAGE THAT EACH PAIR OF IMPELLERS CAN BE SELECTED FOR OPTIMUM PERFORMANCE. THIS LEADS TO <50% OF “IN-LINE” COMPRESSOR STAGES.

IN ADDITION COOLING CAN BE INTRODUCED BETWEEN STAGES.


THE INTEGRALLY GEARED COMPRESSOR HAS THE HIGHEST EFFICIENCY AND A LOWER CAPEX.

Integrally Geared CompressorsAdvantagesAdvantages

All components in contact with wet corrosive gas mixtures, can be manufactured in acid resisting materials.

Pinion shaft arrangement.


Gearbox can be arranged with up to four pinion shafts driven from a single bull wheel.

Machine Materials

FOR CO APPLICATIONS ANFOR CO2 APPLICATIONS AN EROSION/CORROSION RESISTANT MATERIAL IS SELECTED FOR THE IMPELLERS I.E. :-IMPELLERS I.E. :x3 CrNiMo 13.4

FOR WET CO2 APPLICATIONS SUCH AS OXYFUEL, THE STANDARD VOLUTE MATERIAL IS UPGRADED TO : x3 CrNiMo 13 4TO : x3 CrNiMo 13.4



CO2 Compression

Process Integration




Typical Compressor Performance

CO2 Compression

yp p

2

Integrally geared centrifugal compressors

Suction = 1 bar abs*Discharge = 200 bar

RG125

5

160


*SUCTION PRESSURE HAS A DIRECT INFLUENCE ON COMPRESSOR SIZING, POWER CONSUMPTION, & CAPITAL COST.

CCS Compression DutiesInfluence of Capture PressureInfluence of Capture Pressure

CO2 compressors with different suction pressures

120

140Influence of Capture

55

37

100

80

50

72

95100100

80

52

40

60

80

100

120

RG s

ize

%

%

%

%

%

%

%

(suction) Pressure on compressor size, power consumption and capital cost.

Ch t d th 35

0

20

0 1 2 3 4 5 6 7 8 9 10 11

suction pressure bara

RG Type Size coupling power Cost

%Charts drawn on the basis of constant mass flow (66.4 kg/s), and a final discharge pressure of 180 bar abs.

RG Framesize

CO2 compressors with different suction pressures

8

76

7

8

9

terc

oole

rs

Curves plotted for capture pressures of 1.1 & 1.7 bar abs (typical of amine scrubbing,

6

54

3

65

1

2

3

4

5

6

umbe

r of s

tage

s an

d in

tg,Selexol, Rectisol, etc.), 5.0 bar abs (e.g. chilled ammonia), and 10 bar abs (IGSC with 100% CO capture)


0

1

0 1 2 3 4 5 6 7 8 9 10 11

suction pressure bara

nu

Number of impellers number of intercoolers

CO2 capture).

Typical CO2 Compressor Schemewith De-Hydrationy

Inlet (100% flow) 20% Hot (regen) Recycle Discharge (100%flow)AS valve1 AS valve2 AS valve3AS-valve1 AS-valve2 AS-valve3

WET STAGES DRY STAGES

11 2 3 4 5 6 7120%flow

Cooler/Sep.

Fixed bed drier

AftercoolerCooler/Sep.

IGV

100%flowNOTE

Intercoolers 1,2, & 3 not shown for clarity


Fixed bed drierCondensate Removal

CO2 Purification during Compression –Removal of SOx, NOx and HgRemoval of SOx, NOx and Hg

THE INTEGRALLY GEARED CENTRIFUGAL COMPRESSOR ALLOWS THE EASY INTRODUCTION OF SIDE-STREAMS, GAS DE-HYDRATION AND OTHER PROCESS STEPS DURING THE DIFFERENT STAGES OF COMPRESSION !

e.g. SOx removal NOx removal

Wet CO2stream with contaminants

Dilute H2SO4

Dilute HNO3removed in

d t


HNO3 & Hg removed in condensate

condensate

High Capacity Compressor Trains

High capacity CO2 Compressor with Steam Turbine Drive

g p y p

COMPRESSOR TYPE RG140/05 (SHOWN)MAX. NO. OF STAGES : 7MAX. POWER RATING : ~50 MWTURBINE DRIVE SPEED : OPENTURBINE DRIVE SPEED : OPENTURBINE TYPE : CONDENSINGEXHAUST ARRGT. : AXIAL

FOR UTILITY POWER STATION APPLICATIONS THE STEAM BALANCE FOR


FOR UTILITY POWER STATION APPLICATIONS THE STEAM BALANCE FOR THE MAIN POWER PLANT SHOULD INTEGRATE THE STEAM REQUIREMENTS FOR THE MAIN PROCESS COMPRESSORS (ASU & CO2)

High Capacity Compressor Trainsg p y p

3500 TPD AIR SEPARATION TRAIN DURING ERECTION

2 x 3500 TPD ASU TRAINS (EACH WITH A DOUBLE ENDEDA DOUBLE - ENDED 80 MW STEAM TURBINE DRIVER) DURING WORKS PACKAGING AND


TESTING PRIOR TO DESPATCH.

Energy Integrationgy g

TO ACHIEVE OPTIMUM PLANT EFFICIENCIES, ENERGY INTEGRATION SHOULD BE CONSIDERED.

WHILST RECOVERY OF LOW GRADE HEAT FROM THE CO2 COMP INTERCOOLERS IS DIFFICULT, THIS IS OF SIGNIFICANT IMPORTANCE FOR OXYGEN BASED PROCESSES WHERE ASU AIR COMPRESSION HEAT CAN BE RECOVERED IN AN ORGANIC RANKINE CYCLEBE RECOVERED IN AN ORGANIC RANKINE CYCLE.



CO2 Compression

Process Integration




CO2 Pipeline Schemes

Beulah Head Station : 45 MW Compression to 200 bar Operational since 1997 : 1,500,000 t pa CO2 (initial)Current transfer rate : ~ 2,250,000 tpa Planned future rate : > 3,000,000 tpa

Pipeline >200 miles North across the Canadian border


Dakota Pipeline Compressor during Works Testing

8-stage Integrally g g yGeared CO2 Compressor for Gas Transport & Injection

Type RG 080-08

Flow: 68 760 m³/hPressure: 1.15 bar -

187.0 barPower: 13 235 kW

Total installed power : 45 MW in three compressor units feeding into the Beulah/ Weyburn 200 mile high


y gpressure (~220bar) pipeline.

Dakota Pipeline Experience

IN 1997 WHEN THE DAKOTA STATION WASIN 1997, WHEN THE DAKOTA STATION WAS COMMISSIONED, THE TWO CO2 COMPRESSORS OPERATED IN PARALLEL, JOINTLY FEEDING THE 200 MILE PIPELINE TO ENCANA AT WEYBURN .

THE PIPELINE WAS DESIGNED TO OPERATE WITH THE CO2 IN THE SUPER-CRITICAL PHASE TO MINIMISE THE TRANSMISSION POWER.

IN 2007 A THIRD COMPRESSOR WAS ADDED IN BEULAH TO INCREASE THE INJECTION RATE ATBEULAH TO INCREASE THE INJECTION RATE AT WEYBURN; THIS NECESSITATED THE INTRODUCTION OF A BOOSTING STATION AT TIOGA, NORTH DAKOTA (APPROX. HALF-WAY


(ALONG THE LINE) .

Dakota Pipeline Experience

SINCE 1997, THE DAKOTA COMPRESSORS HAVE OPERATED WITH VERY HIGH AVAILABILTYOPERATED WITH VERY HIGH AVAILABILTY .

ALTHOUGH SOME TEETHING PROBLEMS DID OCCUR DURING EARLY RUNNING, THEOCCUR DURING EARLY RUNNING, THE SPECIALLY DEVELOPED CARBON RING SHAFT SEALS HAVE BEEN A GREAT SUCCESS.

PARTICULAR TO THE BEULAH PROCESS PLANT, THE GAS COMPRESSED IS “BONE DRY”, AND COMPRISES ~97% CO2 , >1% H2S AND >1.5% HYDROCARBONSHYDROCARBONS.

SPECIAL MEASURES WERE TAKEN WHEN DESIGNING THE SYSTEM CONTROL, DUE TO THE


S G G S S CO O , U OUSE OF FIN-FAN GAS COOLERS OPERATING IN LOW AMBIENT TEMPERATURES.


CO2 Compression

Process Integration





MAN TURBO OFFER A COMPLETE SOLUTION FOR ALL THE COMPRESSION REQUIREMENTS ASSOCIATED WITH THE OXYFUEL PROCESS.

MAN TURBO CAN ASSIST IN FULLY INTEGRATING THE CO2 TREATMENT AND CONDITIONING STEPS WITHIN THE COMPRESSION PROCESS.

HEAT INTEGRATION TECHNOLOGY IS ALSO AVAILABLE USING A WIDE VARIETY OF MAN TURBO - MACHINERY SOLUTIONS.

MAN TURBO OFFER WORKS PACKAGING AND TESTING OF THE WORLDS LARGEST ASU & CO


TESTING OF THE WORLDS LARGEST ASU & CO2

TURBOMACHINERY TRAINS.

Thank you

MAN T battentionThank you

for your

MAN TurboEngineering the future –since 1758

Engineering the Future –Since 1758.

attentionsince 1758.

MAN Turbo AG R. W. Allen 07.09.2009 < >35Panel Discussion – 1st OxyFuel Conference - Cottbus

Documents

02 - R. Allen (Man Turbo) Quality Meeting for... · Integrally-geared Compressors ... Cottbus MAN Turbo AG R. W. Allen 07.09.2009 < 10 > ... HP CO2 Compressor RG 040/08 8-stage