Enhanced Cryogenic Air Separation

A proven Process applied to Oxyfuel

Future Prospects
Dr.-Ing
Dr Ing. Gerhard Beysel
1st Oxyfuel Combustion Conference
Cottbus, Sept 8th, 2009
 Agenda

1 Introduction

2 Air Separation Technologies

3 Potentials for Power Savings and Cost Reduction

4 Potentials for Large Capacities and Oxygen Demand for New

Applications

5 Innovative Improvements at Cryogenic Air Separation

Linde AG Engineering Division 2 Bey/L/092009/Cottbus.ppt

 The Linde Group
The Divisions

Linde Gas Linde Engineering

((Headquarter Munich, Germany)

y)

50 000 employees 2006 Sales 17 billion US$

Linde AG Engineering Division 3 Bey/L/092009/Cottbus.ppt
 Linde Engineering Division
Product Lines & Key Plant
Types
Olefin Plants Natural Gas Plants

Products: — Products:
— Ethylene — LNG
— Propylene — NGL
— Butadiene — LPG
— Aromatics — Helium
— Polymers — NRU

Hydrogen and Synthesis Gas Plants Air Separation Plants

— Products: — Products:
— H2/CO/Syngas — Oxygen
— Ammonia — Nitrogen
— Gas removal — Rare gases
— Gas purification

Linde AG Engineering Division 4 Bey/L/092009/Cottbus.ppt

 Carbon Capture Technologies (CCS)
- From the ASU Perspective -

Linde
Technology Process Portfolio

1. Pre-Combustion Gasifi Gas CO2

Liquefaction
ASU er CO Shift cleaning
g
&
(IGCC) (Rectisol) Compression

Feedstock CO2

Feedstock

CO2
2. Oxyfuel ASU Boiler DeSOx DeNOx
Liquefaction
&
(Oxycoal) Compression

CO2

Feedstock

3. Post-Combustion DeNO
CO2 capture
Boiler DeSOx
x
&
(PCC) Compression
p

CO2

Linde AG Engineering Division 5 Bey/L/092009/Cottbus.ppt

 Air Separation Plants
Simplified Air Separation Process

Air compression, heat exchange, refrigeration, product

-precooling and -purification rectification and internal compression distribution

Linde AG Engineering Division 6 Bey/L/092009/Cottbus.ppt

 Alternative Air Separation Technologies

Cryogenic Air Separation (ASU)

 the principles invented one century ago (Dr. Carl von Linde)
 developed for large volumes of oxygen and nitrogen with high purities
 commercialized for industrial application in a wide range
 the source for Industrial Gas Companies supply schemes
 Continuous development and improvement , >25% power saving possible

Polymeric Membranes and Moleculare Sieves (PSA, VSA)

 advantageous for small volumes - at lower purities
 produced at ambient temperatures and as needed on-site

Oxygen Production by Chemical Air Separation (MOLTOX)

 Developed and pilot tested by Air Products with DOE funding in early 1990s
 >40% power saving predicted, compared with cryogenic processes
 Status and future of the process unknown (material- and corrossion problems)

High Temperature Ceramic Membranes (ITM)

 Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
 150 tpd under development;
 >30% power saving predicted

Linde AG Engineering Division 7 Bey/L/092009/Cottbus.ppt

 Alternative Air Separation Technologies
- Potentials to Reduce Power Consumption and
Cost
Cryogenic Air Separation (ASU)
 the principles invented one century ago (Dr. Carl von Linde)
 developed for large volumes of oxygen and nitrogen with high purities
High ++
 commercialized for industrial application in a wide range
 the source for Industrial Gas Companies supply schemes
 Continuous development and improvement , >25% power saving possible

Polymeric Membranes and Moleculare Sieves (PSA, VSA)

 advantageous for small volumes - at lower purities medium+
 produced at ambient temperatures and as needed on-site

Oxygen Production by Chemical Air Separation (MOLTOX)

 Developed and pilot tested by Air Products with DOE funding in early 1990s ?
 >40% power saving predicted, compared with cryogenic processes
 Status and future of the process unknown (material- and corrossion problems)

High Temperature Ceramic Membranes (ITM)

 Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
 150 tpd under development; High ++
 >30% power saving predicted

Linde AG Engineering Division 8 Bey/L/092009/Cottbus.ppt

 Alternative Air Separation Technologies
- Potentials to Supply Large Product Flows

Cryogenic Air Separation (ASU)

 the principles invented one century ago (Dr. Carl von Linde)
 developed for large volumes of oxygen and nitrogen with high purities
High ++
 commercialized for industrial application in a wide range
 the source for Industrial Gas Companies supply schemes
 Continuous development and improvement , >25% power saving possible

Polymeric Membranes and Moleculare Sieves (PSA, VSA)

 advantageous for small volumes - at lower purities low
 produced at ambient temperatures and as needed on-site

Oxygen Production by Chemical Air Separation (MOLTOX)

 Developed and pilot tested by Air Products with DOE funding in early 1990s ?
 >40% power saving predicted, compared with cryogenic processes
 Status and future of the process unknown (material- and corrossion problems)

High Temperature Ceramic Membranes (ITM)

 Developed and pilot testing (5t/d) since 2005 by Air Products with DOE funding
 150 tpd under development; ?
 >30% power saving predicted

Linde AG Engineering Division 9 Bey/L/092009/Cottbus.ppt

 Typical Oxygen Demand for New Applications

New Applications Capacity [MW] Oxygen [tons/day ]

IGCC (demo) 250 - 300 MW - 2.000 1)

IGCC, Oxyfuel (demo) 300 - 600 MW 2.000 - 5.000 1)
CTL,, Polygeneration
yg (project)
(p j ) 1500 MW
25.000 1)
GTL (demo) 12.000 bpd 2.500 2)
GTL (commercial 35.000 bpd 7.000 2)
scale)
GTL (commercial 140.000 bpd 30.000 2)
scale)
Cryogenic ASUs: Single train sizes with a capacity of 5.000 tons/d are available
capacities < 7.000 ton/d under development

1)
Low puity oxygen <95%
95%
2)
High purity oxygen >99,5%

Linde AG Engineering Division 10 Bey/L/092009/Cottbus.ppt

 Cryogenic Air Separation – Capacity Increase

1902 : 2006 :
5 kg/h 1,250 Mio kg/h
(0,1 ton/day) (30.000 ton/day)
Linde AG Engineering Division 11 Bey/L/092009/Cottbus.ppt
 Air Separation Plants – Shell „Pearl“ GTL Project
Qatar
30 000 tons/day Oxygen
30.000

Linde AG Engineering Division 12 Bey/L/092009/Cottbus.ppt

 Air Separation Plants – Shell „Pearl“ GTL Project
Qatar
30 000 tons/day Oxygen
30.000

Linde AG Engineering Division 13 Bey/L/092009/Cottbus.ppt

 Large Tonnage ASU
Coldbox Shipment for „Pearl“ GTL project

Linde AG Engineering Division 14 Bey/L/092009/Cottbus.ppt

 Tonnage Air Separation Plants
Mega Plants for new Applications

Cryogenic Air Separation Process Optimization

Linde AG Engineering Division 15 Bey/L/092009/Cottbus.ppt

 Air Separation Process
Conventional Design (mit Einblaseturbine)

PGAN
GOX
5.5--6 bar

ar
1.05 ba

onne
Niederdruckkolo
Wärmetauscher
Booster

Turbine

ator
Kondensa

G
UKG
 Oxygen: 95%, gaseous, at ambient pressure

ochdruckkolonne
5.3-5.8 bar
Features:

Ho
 PNitrogen: up to 30% of airflow available

Linde AG Engineering Division 16 Bey/L/092009/Cottbus.ppt

 Air Separation Process Advanced Alternative
Design
(mit warmer PGAN-Turbine)
Power Wärme/Abwärme

GOX
5.2-5.7 bar
G
POWER

5.5-6 bar

1.05 bar
PGAN
AIR Vorkühlung Adsorber
1.2-1.3 bar

R t
Restgas

Niederdruckkolonne
Wärmetauscher
Booster

Turbine
1

Kondensator
1

 Oxygen: 95%, gaseous, at ambient pressure

UKG
G
Features:

Hochdruckkolonne
 reduced energy consumption/power recovery by

5.3-5.8 bar
expanding

5
PGAN

 heat integration
Linde AG Engineering Division 17 Bey/L/092009/Cottbus.ppt
 Air Separation Process
Advanced Alternative Design (“Dual Reboiler”-
Design)

GOX
5 bar

bar
4.5

1.05 b

derdruckkolonne
Nied
Wärmetauscher
Booster

Turbine

densator 2

UKG
Kond

U
ondensator 1
 Oxygen: 95%
95%, gaseous
gaseous, at ambient pressure

Ko

Hochdruckkolonne
e
Features:

4.3 bar
 reduced process air pressure

 reduced power consumtion

Linde AG Engineering Division 18 Bey/L/092009/Cottbus.ppt

 Air Separation Process
Advanced Alternative Design (3-column Design)

GOX
4..5 bar

1.05 bar
Wärmetauscher

Kondensator 2
erdruckkolonne 2
Booster

Turbine

UKG
Niede uckkolonne 1
nsator 1
 Oxygen: 95%
95%, gaseous
gaseous, at ambient pressure

Konden

Hochdruckkolonne
e
Niederdru
Features:

4.3 bar
 reduced process air pressure

 reduced power consumtion

Linde AG Engineering Division 19 Bey/L/092009/Cottbus.ppt

 Air Separation Units
Cryogenic Oxygen / Specific Energy
Consumption

Conventional Process Schemes / - Applications

kWh/t (short ton)

kWh/Nm³ 1) kWh/Nm³ 2) kWh/t (metric ton) 3)
(= 907,2 kg) 3)

Conversion Figures:

1 O,95 699 635

0,35 kWh/Nm³ O,33 kWh/Nm³ 245 kWh/t 222 kWh/t

Conventional ASU, Oxygen Purity >99.5%

1) 2) 3)
used by ASU vendors (Linde et al) and commonly used for process calculation used by Gas Companies 1 Nm³
= 1,429 kg
Linde AG Engineering Division 20 Bey/L/092009/Cottbus.ppt
 Air Separation Units
Cryogenic Oxygen / Specific Energy
Consumption
Advanced Process Schemes for New Applications, e.g. IGCC,
Oxyfuel, IGSC

kWh/t (short ton)

kWh/Nm³ 1) kWh/Nm³ 2) kWh/t (metric ton) 3)
(= 907,2 kg) 3)

Advanced, energy optimized ASU, 95 % Purity Oxygen

0,25 0,237 175 159

Power consumption reduced by > 25% !!

Above Figures are related to 100% Oxygen (contained Oxygen), normal ambient conditions for design: 20°C, 15°C CW, 60% rel. humidity, at sea
level
Linde AG Engineering Division 21 Bey/L/092009/Cottbus.ppt
 Air Separation Plants
Mega Plants for new Applications

Power Plant Specific

p Requirements
q and their consequences
q

Linde AG Engineering Division 22 Bey/L/092009/Cottbus.ppt

 Air Separation Units for Power Plants Specific
Requirements

Specific Power Plant Requirements:

 lowest possible power consumption

 CAPEX and OPEX optimization

 operation range from 60 to 105%

 load change > 2% per minute

 oxygen purity 95%

 low product pressure

Differences between Power Plant Standards and conventional Industrial Gases

Standards

Linde AG Engineering Division 23 Bey/L/092009/Cottbus.ppt

 Air Separation Units
Specific Requirements for Power Plants

If project specific requirements:

 Design margin of 5%,

 turndown to 63%,
 design for maximum ambient conditions,
 liquid production

are not to be considered for design,

potential for further power saving of 8%.

Linde AG Engineering Division 24 Bey/L/092009/Cottbus.ppt

 Air Separation Units for Power Plants
Air Compression Efficiency

Impact of Turndown Requirement on Main Air Compressor Efficiency

(For a typical ASU)

Turndown Power at motor terminal Additional power

Comparison

75 to 80% 18 500 kW 100 %

63% 19 100 kW + 600 kW 103 %
56% 19 500 kW + 1000 kW 105 %

Linde AG Engineering Division 25 Bey/L/092009/Cottbus.ppt

 Air Separation Units for Power Plants
Air Compression Efficiency

Impact of Different Ambient Air Temperatures

Ambient Air Temperature -17°C 9°C 30°C 33°C

Effective Air Volume Flow 91% 100% 107% 109%

plus 5% design margin

plus turndown requirement

Linde AG Engineering Division 26 Bey/L/092009/Cottbus.ppt

 Load change scenario: Ramping of process
parameters
 Target > 2%/min – fluctuation of oxygen purity?

Load change scenario - conventional process scheme considered

ramping > 4 %/min

400000 1

0,99
350000

0 98
0,98
300000
Oxygen Purity
0,97

250000
0,96
Nm³/h]

O2 [%]
Mair
200000 0,95
MGOX

0,94 O2_%
150000

0,93
100000
0,92

50000
0,91

0 0,9
0 2000 4000 6000 8000 10000 12000 14000
Time [sec]
Linde AG Engineering Division 27 Bey/L/092009/Cottbus.ppt
 Air Separation Units for Power Plants
Summary, Low Power Consumption

Steps to low power consumption of ASU:

 apply highly efficient air separation process

 select appropriate compressor model

 identify possibilities for power/heat integration

 pick advantageous driver option

 check operations requirements carefully (turn down, design margin, etc.)

Linde AG Engineering Division 28 Bey/L/092009/Cottbus.ppt

 Advanced Cryogenic Air Separation
- innovative improvements for new applications

 Advanced Structured Packings instead of sieve tray columns available

reducing pressure drop , increasing turndown capacity

 Advanced pprocess control systems,

y ALC ((AutomaticLoadChange)
g )
available
Dynamic Simulation

 Compressors with higher efficiency, larger turndown range development

 High efficient Heat Exchangers available

 Advanced process schemes 1) available

1) Large
g Scale Low Purity
y Oxygen
yg Requirement
q ((e.g.
g 95%)) - is a novaltyy in Cryogenic
y g ASU applica
pp
leads to a step change energy reduction compared to traditional applications !

Linde AG Engineering Division 29 Bey/L/092009/Cottbus.ppt

 Linde Engagement in CCS – Oxyfuel

Linde has built an air separation plant and a CO2 purification and liquefaction
plant for Vattenfall’s first oxyfuel pilot plant for coal-based power generation
with CO2 capture.

Linde
Portfolio

Oxyfuel Combustion
CO2 to Storage

Air Separation Unit H2O Condensation CO2 Liquefaction

CO2 Recycle N2 Free Flue Gas

Oxygen
Combustion Steam Power Generation
& &
Feedstock Steam Generation Heat Recovery

Linde AG Engineering Division 30 Bey/L/092009/Cottbus.ppt

 Groundbraking Ceremony May 2006

Linde AG Engineering Division 31 Bey/L/092009/Cottbus.ppt

 Oxyfuel Pilot Plant Schwarze Pumpe –
3-D Model

Linde AG Engineering Division 32 Bey/L/092009/Cottbus.ppt

 Oxyfuel Pilot Plant Schwarze Pumpe
Official Inauguration and start-up: Sept. 9th 2008

Boiler

ASU
Dust filter

DSU

FGC

CO2 plant Control room

Linde AG Engineering Division 33 Bey/L/092009/Cottbus.ppt

 Vattenfall Oxyfuel Powerplant Schwarze Pumpe
Linde Scope: ASU, CO2 Plant;
Technologiepartnership

Linde AG Engineering Division 34 Bey/L/092009/Cottbus.ppt

 Vattenfall Oxyfuel Powerplant Schwarze Pumpe
ASU with LCO2 Tank

Linde AG Engineering Division 35 Bey/L/092009/Cottbus.ppt

 Vattenfall Oxyfuel Powerplant Schwarze Pumpe
CO2 Plant with LCO2 Tanks

Linde AG Engineering Division 36 Bey/L/092009/Cottbus.ppt

 Linde Engagement

„Coal or petcoke gasification, Oxygen for CO2-free power

generation, Hydrogen for refinery applications, LNG, and Gas To
Liquids, are all energy related development trends where Linde is
engaged and offers appropriate technologies and know-how.
know-how “

Linde - the Pioneers of Air Separation – we are able to respond to

the challenge of producing cleaner fuel & energy for the growing
worldwide
ld id demand.
d d

(Dr. Aldo Belloni , CEO-Linde)

Linde AG Engineering Division 37 Bey/L/092009/Cottbus.ppt

Thank you
for your attention.