Near-Zero Emission Thermal Power Plant using Advanced KM

Near-Zero Emission Thermal Power Plant

using Advanced KM CDR ProcessTM

The Kansai Electric Power Co., Inc.

Mitsubishi Heavy Industries Engineering, Ltd.

5th Post Combustion Capture Conference

September 19, 2019

2


Outline

1. Introduction

2. Study Conditions

3. OPEX & CAPEX Analysis

4. Conclusions

3


1. Introduction

4


Background and Objective

Carbon dioxide Capture and Storage (CCS) is expected to be one of the

major measures contributing to carbon reduction and net near-zero

emission in the near future.

Fossil fuel power plants equipped with CCS can be considered to be zero-

carbon power generation if nearly full CO2 recovery is feasible.

Background

Objective

The objective of this presentation is to investigate the process performance

and plant economic at max. 99.5% CO2 capture ratio that has not been

studied before using KM CDR ProcessTM (Kansai Mitsubishi Carbon Dioxide

Recovery Process).

5


KM CDR ProcessTM – Kansai Mitsubishi Carbon Dioxide Recovery

Flue gas

Treated gas

Reboiler

Condenser

Blower

Regenerator

CW

Quencher

CW

CO2 product

CW

Absorber

CW

Developed in early 1990s with MHI

Amine-based absorption process

Proprietary features including KS-1™ solvent

First commercial plant in 1999

6


Advanced KM CDR ProcessTM and KS-1TM Solvent

Advanced KM CDR ProcessTM

– 30% CAPEX reduction compared to conventional KM CDR ProcessTM

– For new commercial projects after further evaluation and test

KS-1TM Solvent

– High CO2 capacity

– Low corrosiveness

– Low degradation

7


2. Study Conditions

8


Study Conditions

Reference plant is a coal-fired power plant in U.S. with 650 MW gross

output.

Flue gas is pre-treated by typical air purification technologies equipped with

modern coal-fired power plant (e.g., SCR, FGD, and ESP) to meet US

regulation.

Design Specifications

Flue gas rate (Nm3/hr) 1,846,500

CO2 concentration (mol%) 13.5

CO2 capacity (tonne/day) 10,572 – 11,688

CO2 product pressure (kg/cm2g) 130

9


Study Scope

Power plantCO2

AbsorptionSolvent

RegenerationFlue gas

Treated flue gas

CO2 product

CO2

lean solvent

CO2

rich solvent

Stack

Flue Gas Quencher

CO2 Compression

& Dehydration

Scope of CO2 Capture and Compression

Flue Gas Quencher

CO2 Absorption Section

Solvent Regeneration Section

CO2 Compression and Dehydration Section

10


Study Cases

Base case

- CO2 capture ratio: 90%

- Relative absorption packing height: 100%

Study cases

- CO2 capture ratio: 95 - 99.5%

- Relative absorption packing height: 100 - 200%

Base case Study cases

CO2 capture process Advanced KM CDR ProcessTM

Capture ratio (%) 90 95, 99 99.5

Relative absorption

packing height (% as m)100 100 100, 125, 150, 175, 200

11


CO2 Partial Pressure at CO2 Absorber Top

*) Typical coal-fired flue

gas case at 1 bar with

13.5 mol% CO2

CO2 partial pressure

decreases dramatically

after 95%.

More packing height is

necessary to achieve

high CO2 capture ratio.

12


Costing Method

CAPEX (Total Engineering, Procurement and Construction (EPC) Cost)

- Direct cost: Purchased equipment, Instrumentation, Electrical, Piping,

Construction material

- Indirect cost: Engineering, Construction, Transportation, License fee,

Contingency and KS-1TM initial fill cost

OPEX

- Utility: LP steam, Electricity, Cooling water makeup

- Chemical: KS-1TM makeup

Plant availability (%) 90

Electricity cost($/kWh) 0.065

Cooling water makeup cost($/m3) 0.2

Low pressure steam cost ($/tonne) 10

Capital charge factor (CCF) 0.124

Costing Parameters

𝐴𝑛𝑛𝑢𝑎𝑙𝑖𝑧𝑒𝑑 𝐶𝐴𝑃𝐸𝑋 ($

𝑡𝑜𝑛𝑛𝑒 𝐶𝑂2) =

𝑇𝑜𝑡𝑎𝑙 𝐸𝑃𝐶 𝑐𝑜𝑠𝑡 $ × 𝐶𝐶𝐹(1𝑦𝑟)

𝑎𝑛𝑛𝑢𝑎𝑙 𝐶𝑂2 𝑐𝑎𝑝𝑡𝑢𝑟𝑒𝑑 (𝑡𝑜𝑛𝑛𝑒/𝑦𝑟)

13


3. OPEX & CAPEX Analysis

14


OPEX & CAPEX Analysis

Total OPEX & Annualized CAPEX (scale against base value: 100)

Base

caseStudy cases

CO2 capture ratio (%) 90 95 99 99.5 99.5 99.5 99.5 99.5

Absorption

packing height

(% as m)

100 100 100 100 125 150 175 200

Total OPEX &

Annualized CAPEX

($/tonne CO2)

100.0 101.5 104.0 106.0 103.2 102.7 102.8 103.0

Minimum total cost is 150% packing height case for 99.5% capture ratio.

This case is called “Near-zero emission case” in the study.

15


OPEX & CAPEX Analysis

16


4. Conclusions

17


Conclusions

1. Advanced KM CDR ProcessTM with KS-1TM is used to explore the near-

zero emission power generation and the feasibility of high CO2 capture

ratio at 99.5%.

2. A near-zero emission coal-fired power plant that recovers 99.5% of CO2 is

technically feasible using the Advanced KM CDR ProcessTM and KS-1TM

solvent.

3. The near-zero emission case will increase the cost of CO2 captured by

near 3% compared with base case.

Thank you.

Documents

Near-Zero Emission Thermal Power Plant using Advanced KM