THURSDAY 26 SEPTEMBER
Development of a Site-Assembled CO2 Absorber Column
Speaker: Esme Elman, Bechtel
Some potential sites for carbon capture are constrained by access, being located away from ports or other deep-water access. The one-piece absorber column design in Bechtel’s standard 1 million ton per year carbon capture plant design is over 65m high and 16.7m in diameter; to fabricate and test the one-piece absorber column in a low-cost location and then transport to an inland site would be challenging or impossible.
Bechtel has developed an alternative concept for an absorber column that can be assembled or fabricated on site to mitigate such logistics issues.
A range of construction methods were evaluated against criteria such as material cost, fabrication cost, ease of transport and ease of construction. Both circular and rectangular column geometries were evaluated, along with metallic and concrete materials with liners. A best technology selection report was produced with a range of disciplines, covering the various engineering, procurement and construction factors.
Get More for Less :“De-carbonising existing assets – Some lessons learned”
Speaker: Adish Jain and Paul Dickens, Fluor Limited, UK
Decarbonisation programmes are demanding increasing attention and Fluor’s Global new project awards illustrates this trend with a rise from 80+ Energy Transition Projects in 2022 to over 200 projects in 2023.
Lessons learned from two of the case studies of existing facilities illustrate
- A targeted but strategic approach is required at the organisation level to achieve carbon reduction.
- Develop “helicopter view” to identify opportunities at macro level.
- Assess existing facilities remaining life and technology “fit-for-purpose”.
- Assess impact on operations, plant availability and cost to prioritise these opportunities over long period.
- Combine energy transition with phased end-of-life asset renewal for improved return.
In Authors experience, some of the typical short term global opportunities are replacing fuel oil with fuel gas, electrification of combustion equipment, steam pressure rationalisation, recovering vent gases and recycle, flare gas recovery etc. The challenges are production loss during changeover, reduced availability, technology risk and importantly, the mindset to change.
Syngas Conditioning and Decarbonisation: Design, Footprints, Safety and Emissions Criteria from Project Experience
Speakers: Syed Hasan and Sangeeta Ankam, Kent
Net Zero ambition can be realised by sustainable energy transition from fossil fuels to renewables such as Syngas that is derived from scalable Municipal Solid Waste (MSW) gasification units (350 ~ 600 ktpa) to produce sustainable aviation fuel (SAF) or other products.
This presentation defines opportunities for purification, decarbonisation and NOx abatement of Syngas facilities. The Syngas post MSW gasification is cooled via Heat recovery steam generators (HRSG) for further removal of particulates, inorganic species and quenching followed by Compression via steam turbine driver. The Syngas quality is enhanced in Water Shift reactor followed by Acid gases removal using Hydrolysis Reactor and Absorber column employing formulated amine that has higher acid gas loading capacity and mass transfer kinetics to achieve deep removal of both CO2 and H2S that are detrimental to Fischer-Tropsch (FT) Catalyst. The traces of contaminants are removed in Adsorbent beds prior to conversion of Syngas to Hydrocarbon liquids in FT unit and product upgrading is achieved in Hydrocracking and Fractionation unit to enable SAF production. The acid gas (CO2/H2S) is compressed to intermediate pressure for Sulphur removal via redox process and dehydration through adsorbent media. The conditioned CO2 is fiscally metered and piped for sequestration whereas sulphur cake is disposed of via trucks. The aforementioned Syngas to SAF process enables efficient decarbonisation with inherent safety, minimum footprints, reduced life cycle cost, lower GHG and NOx emissions.
Saipem’s Enzymatic Carbon Capture Technology: A Strategic Advance in Industrial Decarbonization
Speaker: Ligia Panà, Saipem
Climate change is one of the most pressing challenges of our time, requiring urgent action from all industrial sectors. As a global leader in engineering solutions, Saipem is committed to developing and implementing cutting-edge technologies that can reduce greenhouse gas emissions and foster a sustainable future.
Introducing the enzymatic CO2 capture solution, Saipem demonstrates the vision and leadership in engineering a sustainable future, setting a new benchmark for environmental care.
The solution developed by Saipem is an innovative enzyme-catalysed carbon capture technology using a non-toxic and non-volatile solvent that excels in rapid CO2 absorption. The technology offers a unique, industrialized approach to decarbonization that combines sustainability, safety, and economic viability. Its modular and pre-engineered packages are a replicable, plug-and-play, perfect for quick and effective carbon-neutral transition, as it reduces onsite work and speeds up project timelines.
By harnessing the power of nature and innovation, the enzymatic carbon capture process can help a wide range of industrial sectors meet their environmental and economic goals and take a substantial step towards consistent environmental responsibility.
Furthermore, its innovative approach allows for the use of low-temperature heating medium for solvent regeneration, leading to OpEx reduction through integration with residual heat or low-grade geothermal sources.
Electrifying the Chemical Value Chain with Photocatalyst
Speaker: Trevor Best, Syzygy Plasmonics
Using a photocatalyst in an electrified reactor can increase efficiency in catalytic cracking and eliminate CO2/NOx emissions when powered by renewable electricity.
Photocatalyst rate has an exponential relationship with both temperature and photon Intensity.
An increase in photon intensity reduces the activation barrier even at a constant temperature, resulting in a higher reaction rate at lower temperatures.
Presenting point:
- Photocatalyst (Mechanism of Catalysis with Antenna-Reactor Photocatalystphotocatalyst
- Reactor Cell (Bulb vs LED: Luminous Efficacy vs Photon Efficiency)
- Data review from test site’s
- CO2 reforming
- Ammonia cracking
- Technology for the electrification sector in Midstream/Downstream
This technology addresses the tri-dilemma: Decarbonization, efficiency, and affordability.
FRIDAY 27 SEPTEMBER
Generating Value Removing CO2, H2S and Mercaptans with a Novel Solvent
Speakers: Marco Oliva, Eni SpA. Giovanni A. Petrachi, Shell Global Solutions International BV
After the implementation of more stringent sales gas specifications affecting CO2, H2S and mercaptans, ENI experienced bottlenecks in the Acid Gas Removal Units operated with MDEA-based solvent, which led to throughput reduction and higher operational costs due to penalties and blending with sulfur-free natural gas.
The test-run performed in the ENI gas production facility showed that the new DM-101 solvent, based on single-amine aqueous solution can meet the new sales gas specifications, achieving mercaptans removal efficiency of 60% and up to more than 90% depending on the operational conditions, without any modification of the existing facilities. The lean solvent temperature and especially the liquid-to-gas ratio are the available operational levers to adjust the mercaptans removal, finding the optimal trade-off between the sales gas specification and the SOx emissions from the Thermal Incinerator stack (via the Acid Gas Enrichment Units off-gas).
The test-run showed that the DM-101 can support the site goals, increasing the operational flexibility and assuring the production continuity, through the compliance with the sale gas specs and the production optimization of the asset, thanks to the exploitation of the sour section of the reservoir.
Benefits of Latest HySWEET® Solvent Formulation: Insights from Recent Operational Units
Speakers: Carmella Alfano, Axens and Renaud Cadour, TotalEnergies
Over the last decade TotalEnergies developed a new gas treatment process by taking advantage of its extensive know-how and experience in sour gas processing. This new solvent technology relies on a hybrid solvent formulation using a mixture of amines and a physical compound to simultaneously remove acid gases and mercaptans. Additionally, this “all in one” solvent also simplifies the gas treatment chain, requires less energy and thus reduces the carbon intensity of the plant.
This technology has first been demonstrated and implemented in existing units of the Lacq plant since 2007. The last formulation based on MethylDiEthanolamine, Piperazine and a physical compound has been in operation in the SOBEGI industrial complex for 6 years.
Today AXENS is the exclusive Licensor of this new technology and has granted several licenses in the Middle East and North America. Recently the first AXENS’ commercial units have been successfully started-up.
This paper presents the benefits of the HySWEET® technology application on sour gas fields, relying on start-up and operational results.
Hybrid Solvent System Design Approach Upgraded
Speaker: Philip le Grange, BASF
Hybrid solvents, a mixture of aqueous amine solutions and a physical solvent, are frequently used for removal of mercaptan sulfur species and for the energy savings they offer over a conventional amine system. This paper presents BASFs cutting edge approach to these systems.
The design approach upgrade encompassed as a core element lab measurements investigating the gas solubility of CO2, H2S, mercaptans (methyl, ethyl, propyl), COS, CS2 and hydrocarbon components in the hybrid solvent. In open literature the data for hybrid solvents is scarce or not available. If any information is published, often only one solvent composition was investigated, whereas the impact of different concentrations of the physical solvent or different ratios between amine and physical solvent was not part of the research activity. Based on the lab test result comprising gas solubilities, physical properties, and reaction kinetics a rate-based simulation model was developed.
For model validation an extensive test program was performed in BASF’s pilot plant. There was a good match between the model and pilot plant data. Next the reengineered simulation model was compared to an industrial reference plant currently using BASFs hybrid solvent with good result.
Unwanted hydrocarbon coabsorption by the solvent is the traditional downside to any hybrid system. A comparison of field data and simulation results is presented for hydrocarbon coabsorption as well as a novel (patented) process configuration to minimize hydrocarbon in the acid gas.
Optimizing The Process Design to Manage the Impurities Effects on CO2‐Rich Streams Processing
Speaker: Paolo Cari, Saipem
As the global natural gas industry accelerates its efforts towards emissions and carbon footprint reduction, carbon capture, utilization and storage (CCUS) plays a key role on this path. In fact, what was once considered a waste emission stream is now emerging as a feed stream for CO2 capture, purification and handling processes. Consequently, CCUS facilities are increasingly essential either as an additional part of any industrial plant or as stand‐alone facilities (i.e. hubs) purposely designed to collect, treat, store and utilize/dispose the CO2‐rich streams from different sources as the primary feedstock.
Due to the nature of the emissions and sources, such as but not limited to post combustion power plants, pre‐combustion gas treatment plants, ammonia/urea production plants, etc., the composition of CO2‐rich streams could vary significantly depending on emitters. Consequently, the CO2‐rich streams resulting from the first capture steps may contain dissimilar amounts of different impurities. Such impurities affect the physical behavior and properties of the CO2‐rich streams and, therefore, have different implications in the process design. In addition, since the concentrations of such species are often a result of co‐absorption or slip phenomena from upstream processes, they are typically not fixed parameters, but rather vary within ranges, requiring the process design to account for wider envelopes.
Therefore, understanding the effects of impurities over the operating and compositional envelope of the CO2‐rich streams becomes of the utmost importance to achieve a robust and flexible design of CO2 handling facilities. Many process and engineering design choices, together with their subsequent CAPEX impact, are driven by this specific issue.
Using case studies based on the EPC Contractor experience gained in executing several CCUS projects, this paper presents a thorough analysis of the impurities in post capture CO2‐rich streams and their effect on the fluid behavior and properties, with a specific focus on the relevant implications on process design considerations for CO2 handling systems relevant to:
- compression facilities
- liquefaction processes
- storage and transportation facilities
- auto‐refrigeration processes
Depressurization of AGR Unit, a Critical and Complex Study for Projects
Speaker: Loic Van-de-Velde, T.EN
During the design of LNG plants, gas treatment, NGL recovery units and Offshore facilities, depressurization study is part of fundamental calculations for the material selection of equipment and flare network design ensuring meeting all the safety design criteria. Until the 5th release of API 521, an empirical approach was clearly defined and commonly used for all types of projects and units. Only a few exceptions on the duration of depressurization were applied on specific cases such as LPG systems or units with large inventory such as slug-catcher finger types.
However, in 2014 with the publication of the 6th version of API 521, the codes and standards knew a major update dealing with a new analytical approach based on Stefan-Boltzmann law and considering different types of fires and a stress-based calculations and performance criterion. The new methodology has been developed based on fire test data from laboratory API recommendations to comply with these requirements.
This paper is built on experiences and feedback attained through recent LNG projects in different world regions and for different facilities. It aims at highlighting the issues of the new types of fire and evaluating their impact on depressurization calculations. The use case of an Acid gas removal unit blowdown with T.EN in-house software LNGDYN® will illustrate the challenges of complex systems (multiple equipment, internals, various operating conditions...) with huge inventory for the flare design.
CO2 Liquefaction: Achieving Feasible Plant Economics and Efficiency Through Improved Compression Duty
Speaker: Onur Serin, Atlas Copco Energas GmbH
In tackling the challenge of carbon footprint and carbon emissions reduction, the liquefaction of CO2 has emerged as one of the most effective methods in transporting captured CO2 and supplying it for use in other industries.
Compressors are essential machinery for CO2 liquefaction. In terms of the process, the traditional (and also most cost friendly) liquefaction method includes the use of external refrigerants such as ammonia (the main purpose of applying an external refrigerant to the process being that the refrigerant isn’t in contact with the CO2 during liquefaction).
In liquefaction processes using ammonia as a refrigerant, CO2 is compressed and liquified after using the ammonia as cooling medium. In a next step, it is transported to the storage location. During the process, CO2 first runs through a separator, where water and other condensed gases are removed from the CO2. After being sent to compression, ammonia is used as cooling medium with help of the heat exchanger, while also being compressed after evaporation and later cooled (thus completing the cycle).
Even though this liquefaction process is, by definition, a cost-feasible solution, capital expenditures (CAPEX) still are an weighty factor in the overall investment decision. This cost is mainly impacted by the compressors needed in the process.
In the application discussed in the paper, the two compression duties (CO2 and ammonia) can be handled in different sections of just one single-skid compressor, instead of two separate units. This makes the compressor footprint in the liquefaction plant more compact, robust and cost-efficient.
Like CAPEX, operational expenditures (OPEX) are primarily defined by the compressors (especially the power consumption cost of the liquefaction process). This is why compressor considerations are essential for plant operators: The combined compressor solution’s package is more optimized in terms of size and equipment cost compared to alternative compression solutions (where CO2 and ammonia are handled on separate compressors units).
Using the examples of current plants in Europe, the paper will discuss the design concept and performance data of handling the two duties through a single compressor. Specifically, the author will be considering the different inlet and outlet conditions for the ammonia cycle and CO2 cycle, respectively, describing how this impacts compressor design and performance (speeds, flow management etc.)
AADZORB Technologies for Gas Treatment and Carbon Capture
Speaker: Georgios P. Lithoxoos, Aramco
In the present paper, we showcase the progress that researchers at Saudi Aramco R&D Center have made, towards demonstrating the cost-effectiveness of a technology option that targets achieving 99.99%+ sulfur recovery inside sulfur recover units (SRUs). This technology, dubbed AADZORB, comes in the form of an SRU tail gas treatment process that uses solid sorbents in two consecutive stages, the first stage for drying the tail gas stream while the second one for removal of H2S from the dehydrated tail gas stream.
In this talk, details on the journey of transforming an idea for cost-effective treatment of SRU tail gas streams (WO 2021/035081 A1) to a demonstration plant will be shared. The demonstration plant will be operational in a US refinery, using a tail gas flow of 1 MMSCFD, during the next 12 months. The discussion will focus on the results obtained during bench- and pilot-scale testing, which convinced the team that the separation capacity and selectivity, as well as hydrothermal stability of the adsorbents make AADZORB very competitive with the industry commercially proven technology.
Based on results from the pilot plant tests, AADZORB technology is expected to achieve sulfur recovery exceeding 99.9% at gas plants and refineries, along with a minimum 20% reduction in capital expenditure (CAPEX) and 30% decrease in operating costs compared to reduction-absorption process for managing 50 ppm of SO2 emissions. Furthermore, AADZORB prepares the SRUs tail gas streams for a cost-effective CO2 capture.
Energy Savings and Mitigation of H2S/CO2 Spikes in Molecular Sieves Gas Drying
Speaker: Jonathan Stain, Arkema
Molecular sieves play a crucial role in the process of drying and purifying natural gas, often being the sole technology capable of achieving dew points compatible with cryogenic processes.
While these units are generally reliable, operational complexities arise when dealing with feed gases containing traces of H2S and / or CO2. The oversight of these contaminants can lead to significant spikes in regeneration, introducing significant operational challenges.
This paper explores solutions to minimize H2S and CO2 spikes during regeneration, with a focus on reducing energy consumption, thereby enhancing the efficiency and reliability of the process.
