Optimization of CO2 capture plant through PROII UAS...

Optimization of CO2 capture plant through

Pro-II UAS programming for new solvent

October 6, 2015

Table of Contents

1. Introduction

2. CCS R&D Outline

3. PRO-II UAS programming

4. Future Plan

Daelim Industrial Co., Ltd.Hyun Shin, Ko / General Manager

1. Introduction

01 | Introduction

2

· Korea’s leading enterprise group

with 76 years’ history

· In the top 100 Korean companies list

since inception 60 years ago

· The first Korean Company operating

in the Middle East

· The first Korean Company to earn

USD by overseas construction work

· Ranked 18th in Korea’s business

groups

· Implements projects in 35 countries

· Korea’s leading construction/

petrochemical group

· Listed in the DJSI World Index

in 2013, 2014

· Seeks to be a global developer

for petrochemical and

power generation sectors based

on global top-tier EPC

capabilities

Global

Developer

Overview

Daelim Group

Since

1939

USD 16.4 Billion

in Asset Size

of 14 Affiliates

Founded in 1939, the Daelim Group is Korea's representative group composed of

14 affiliates including power generation, logistics, manufacturing and IT companies,

based on Daelim Industrial, a global EPC contractor and Petrochemicals company.

01 | Introduction

3

Plant Petro-

chemical

Unit

Civil

Engineering

Building

& Housing

Yeochun

NCC

(YNCC)

PolyMirae

(PMC)

KRCC

Daelim Industrial Co., Ltd.

Engineering &

Construction Unit

Petrochemical

Unit

Daelim Corporation

Daelim C&S

Daelim Motor Co., Ltd.

Trading &

Manufacturing

Daelim EnergyEnergy

Korea Development

Corporation

Samho International

Construction

Daelim University

College

Daelim Contemporary

Art Museum

Education &

Culture

Daelim I&SInformation

Technology

Ora Resort Co., Ltd.Leisure Service

BusinessPortfolio

Daelim Group

Group

01 | Introduction

4Singori Nuclear Power PlantSahara PDH, Saudi Petron RMP-2 Refinery, Philippines

Overview

Highlights

· World’s largest polycarbonate plant (260,000MTPA,

Kayan Polycarbonate, Saudi, ’2007~’2010)

· World’s largest PDH plant (PDH 467,000MTPA, PP

450,000MTPA , SAHARA AI-Waha PDH/PP, Saudi, ’2006~’2008)

· Awarded Saudi SABIC's Best Project in 2008

(Ibn Zahr PP III U&O Project, Saudi, ‘2006~‘2008)

· The largest project award in Korea within South East

Asia region (Petron RMP-2 Refinery Project, USD 19.8

billion, Philippines, ’2010~’2014)

· Four Petrochemical units invested by US oil major

Chevron Phillips (NCP Polymer Project, Saudi, ’2007~’2011)

· The first Butanol Plant in Saudi Arabia and the largest in

the world (SABUCO Butanol & Syngas Project, ’2013~’2015)

· The largest Refinery Expansion Project in Oman

(Sohar Refinery Improvement Project, ’2013~’2016)

Plant

· More than 600 projects completed or underway in 36 countries

· 40 years’ skilled and sophisticated design competencies

with adoption of advanced engineering in 1974

· Total service offered including FEED (Front End Engineering

Design ), EPC (Engineering Procurement Construction) and

O&M (Operating and Maintenance)

· O&M competency secured through petrochemical

plant operations (Petrochemical Business Division built up

know-how on plant operations for more than 30 years)

· The most number of bids invited by major clients in

the Middle East (80 bids invited between 2010 and 2013)

Daelim Industrial

E&C Unit

Plant

01 | Introduction

5

8.2 6.0

7.7

2012

7.9

2013

8.2

2014

New Orders (USD billion)

7.06.5 5.9

Sales (USD billion)

2012 2013 2014

388

177

60

Operating Profit (USD billion)

2012 2013 2014

(FY2014)

52%31%

17%

59%23%

18%

(FY2014) Building &

Housing

Civil

Plant Building &

Housing

Civil

Plant

FinancialHighlights

Daelim Industrial

E&C Unit

New Orders Sales

USD Billion USD Billion

2. CCS R&D Outline

02 | CCS R&D Outline

7

� CO2 Capture Technology from Flue gas


8

� Characteristic of CO2 capture plant from flue gas

� Very low pressure� High CO2 concentration� Oxygen� SO2� Huge gas volume� High corrosive environment

Low Energy consuming New Capture Technology


9

Effective Design of Process and Scale-up

(DAELIM)Developing Solvent

(KEPCO Research & Institute)

Cost / Quality Competitiveness

Advanced Solvent

Power Plant

BusinessPlant Engineering

Plant Construction,

Integration with Power plant

(KOREA Power, KEPCO E&C,

POSCO E&C)

World Best CO2 Capturing

� R&D Needs



10

Developing Solvent(KEPCO Research & Institute)

Cost / Quality Competitiveness

Advanced Solvent

Power Plant

Business Plant Engineering

Plant Construction,

Integration with Power plant

(KOREA Power, KEPCO E&C,

POSCO E&C)

� R&D Needs (Advanced Solvent / Power Plant Business)


11

� R&D Needs (Advanced Solvent / Power Plant Business)

Advanced Solvent Power Plant Business

KEPCO Research & Institute)KOREA PowerKEPCO E&CPOSCO E&C

• Many experiences in the development of advanced solvent for Post-combustion (Coal fired)

• Plant Construction

• Plant Operation & Maintenance

• Integration with Power plant

• Optimization of Energy utilization

Good advanced proprietary solvent (KoSol series)Good construction & integration



12

Effective Design of Process and Scale-up

(DAELIM)

Cost / Quality CompetitivenessAdvanced Solvent

Power Plant

Business

Plant Engineering

� R&D Needs (Plant Engineering)


13

� R&D Needs (Plant Engineering)

Plant Engineering

Daelim Industrial Co., Ltd.

Engineering Simulation

• Many experiences in Amine Treating Process (Refinery and Gas plants)

• Basic Design / FEED Design / Detail Design

• Many Simulation programs• Experiences in simulation of CO2 capture

process using specialized program in Amines

Good engineering, Good commercial programs

How does it work on new advanced solvent ??


14

Cost / Quality CompetitivenessAdvanced

Solvent

Power Plant

BusinessPlant Engineering

World Best CO2 Capturing� R&D Needs (Plant Engineering)

DEDICATED NEW SIMULATION PROGRAM


15

Part 1

Low energy consumingCO2 capturing solvent

developing

KEPCO Research & Institute

Part 2

CO2 capture process basic design

DAELIM

Part 3

CO2 capture plant construction and

operation

KOMIPO / POSCO

Part 4

CO2 capture plant integration with

power plant

KEPCO E&C

Overall R&D Project

Development of Commercial Package of 10MW Post-combustion Advanced Amine CO2

Capture Technology

KEPCO Research & Institute

Monitor / Adjustment / Guide

� R&D Organization and R&R


16

Demonstration Plant

Coal power plant 150 MW

Pilot Plant

Coal power plant 10 MW

Test Bed

Coal power plant 0.1 MW

Boryeong Location ?

Improvement suggestion

Scale-up study Demonstration

Boryeong

� Scale-up

� Large scale pilot plant


17

10 MW CO2 capture plant view

3. PRO-II UAS Programming

03 | Pro-II UAS Programming

19

PRO-II AA BB CCMerit

- Active technical support

- Similar experience

Many users- Specializedprogram for amine treating unit

- Many experiencein amine treating

Specialized program for amine treating unit

De-MeritGeneralized on hydrocarbon processing

- Relatively highercost

- Generalized on hydrocarbon processing

Not allow to open the source code Not proven

Remarks Korea agent Korea agent Korea agent No Korea agent

� Why did Daelim choose Pro-II?


20

� Development of Process Simulation with KoSol1) Thermodynamics modeling and its incorporation into PRO II

* User Library for new amine components

* User-added thermo for reaction equilibrium calculation

- Kent Eisenberg Model (Ionic equilibrium reaction and Vapor-liquid equilibrium(Henry’s law))

* Enthalpy calculation

* Utility program for parameterization of equilibrium constants

2) Mass-transfer modeling and its incorporation into PRO II

* User-added mass-transfer for the absorption kinetics

* Utility program for parameterization of mass-transfer coefficient

3) Software configuration

DLL for user-added thermodynamics model

DLL for user-added mass-transfer model for RATEFRAC


21

� Work Flow for Process Simulation Development (KoSol)

Properties of KoSol

� Heat of vaporization input� NRTL parameter value

input� Henry’s coefficient� Etc.

Set Equilibrium Reaction/ Mass transfer

Equations

UAS Programmingfor Reaction

in PRO/II

� Reaction� Mass-transfer

Parameterizationw/ Experimental data

Validation Workfor UAS

Programing

CCS Process Simulation (test)

ActualOperating Data

Tuning Work forUAS Programming

� component properties� k-value� liquid enthalpy� RATEFRAC enhancement� Etc, if required CCS Process Simulation

(150 MW)

SimSci Scope


22

Daelim’s scope SimSci’s scope

• Providing the required Property Data for new solvent

• Measure the heat of reaction

• Validation the built-up UASs together with Invensys

• Build the CCS simulation model

• Gathering the actual operating data in the pilot plant

• Tuning work of UASs based on operating data

• Build the final CCS simulation model and Basic Design

Package

• UAS for Equilibrium reactions from experimental data

– User Added Subroutine program (UAS) is made to attach in the PRO/II

– UAS is communicated with the source code in PRO/II.

– Equilibrium reactions to be generated based on Kent Eisenberg equation and it to be developed together with Invensys.

• UAS for mass transfer from experimental data

– User Added Subroutine program (UAS) is made to attach in the PRO/II

– UAS is communicated with the source code in PRO/II.

– Mass transfer UAS to be built to predict absorption kinetics

• Training for UAS building

– Training for the procedure of building UAS

� Scope split between Daelim and SimSci


23

� Registration of New Databank (KoSol)1) Existing Components

* Using a SIMSCI databank or a PRO II Process databank

2) New Components

* Estimation by PROPRED system (registration of molecular structure)

3) Added experimental value (ex : boiling point, etc)

* Using “Experimental Data and Calculation Options”

4) Protection

* Component information (Name, Structure, etc)

* Property data (Temperature dependent parameter, Physical property data, etc)


24

Work title Objectives Activities Data required

Thermo/mass-

transfer core program

Create prototype program to predict VLE based on reactions.

Create a prototype on VBAComponents and

expected reactionsObjective acid components

Create prototype program to predict mass-transfer coefficient based on

Hatta TheoryCreate a prototype on VBA

Parameterization

Determine parameter values to predict VLE based on reactions.

Determine reaction equilibrium Constant

Loading curve data at plural temperature levels in

expected operation range of Temperature

Determine activity Coefficient

Data on evaporation of Amines

Determine parameters for enthalpy

Determine superficial heat of vaporization

Heat of reaction

Heat capacity of the mixture Heat capacity data

Determine parameter values to predict density, viscosity

-Density and viscosity of the

solution

Determine parameter values for mass-transfer coefficient based on

Hatta Theory

Determine paramters on Hatta number (k/D)^0.5

Data on enhancement of absorption rate by adding

additives.

� Detail activities per step (1/2)


25

Work title Objectives Activities Data required

Incorporation to PRO/II

User added subroutine for VLE (directly connected to

PRO/II) and mass-transfer (connected to RATEFRAC)

Check the VLE and mass-transfer predicted by UAS are the same with those by

stand alone programs

-

Test by PRO/II

prototype

Create a prototype simulation file on PRO/II using the features developed in this work and check if they work

well.

-The expected process flow diagram and feed flowrate.

� Detail activities per step (2/2)


26

10MW Pilot plant

� Commercialized simulation

� Basic design by DAELIM

Dedicated Pro-II UAS programming and Tuning

150MW CO2 capture plant

� Application of dedicated Pro-II UAS

� Basic design by DAELIM

� Transition history of Process simulation for KoSol


27

UnitBefore the

tuning[ A ]

After the tuning[ B ]

Operation[ C ]

Gap %[(B-C)/Cx100]

Duty

of condenserMMkcal/hr 3.17 1.36 1.47 7.4

Duty

of reboilerMMkcal/hr 6.64 5.37 5.63 4.6

Density

for lean/rich

amine solution

kg/m3 1000/906 1130/1039 1117/1038 0.6

� Tuning results of PRO-II UAS

Further sufficient tuning work to be required on the basis of much more operating data.


28

UnitCommercial Program

[ A ]

PRO II UAS

[ B ]

Gap %

[(A-B)/Ax100]

Duty

of condenserMMkcal/hr 28 15.1 46

Flowrate of Reflux ton/hr 44 26 41

Duty

of reboilerMMkcal/hr 76.6 82.8 8.1

Regeneration

EnergyGJ/tonCO2 2.56 2.76 7.8

Density

for lean/rich amine

Solution

kg/m3 1109/998 1100/933 0.8/7

� Comparison with Commercial program

There is an obvious practical optimization of design through PRO-II UAS Program.

4. Future Plan

04 | Future Plan

30

– Addition of function to execute simulation of theoretical tray column:

To reach quickly to the results during many case studies

– Simultaneous application of various packing types in RATEFRAC

Calculation

– Continuously tuning of our program based on various operating data

(The more gathered operating data, the more reliable)

� Further Development for PRO-II UAS Program

Some part of above mentioned items will be executed through another project with

SimSci.

04 | Future Plan

31

� Strategy for Commercialization

– Design optimization through the developed PRO-II UAS Program

– Meet various potential Client’s needs through case studies through the program

– Continuously operating of 10 MW Boryeong CCS facility to verify high reliability of

our CO2 capture technology

– First, application of our CO2 capture technology in Korea CCS Demonstration

project

– Next, entry into Global CCS technology market

– Also, entry into Global CCS EPC market as Global EPC contractor

32

Thank you !

[email protected]

I want to express my thanks to Mr. Hirohama, Ms Miyaoi and

Mr. JC Lee, who are working for Schneider-Electric.


33

– Liquid distribution test By AMT Pacific

� Rectangular absorber (Mok-up)

Optimization of CO2 capture plant through PROII UAS...

Documents

Transcript of Optimization of CO2 capture plant through PROII UAS...