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CO2 Recovery Plants [ Prevention of Global Warming and Air Pollution ] [ ENVIRONMENT ]

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KM CDR Process

Mitsubishi Heavy Industries Engineering (MHIENG) offers large scale, high performance & reliable CO2 recovery plants for application in a wide variety of industries.

MHIENG Technologies Offer a "Large-scale," "High-performance" Plant for CO2 Recovery from Flue Gas MHIENG is proud to present an advanced commercially available CO2 recovery process KM CDR Process (KANSAI MITSUBISHI Carbon Dioxide Recovery Process) which promises enhanced economic performance for plants of wide-ranging capacities. The MHIENG CO2 recovery process utilizes "KS-1," an advanced hindered amine solvent, in conjunction with a line of special proprietary equipment. The technology was developed through cooperation between MHIENG and Kansai Electric Power Company, Inc. (KANSAI). The process is based on an advanced and proven technology for recovering CO2 from various sources of flue gas. Users who adopt this economical process will enjoy benefits such as low energy consumption, low solvent degradation, and reduced corrosion within the equipment.

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What is the KM CDR Process ®

MHIENG offers large scale, high performance & reliable CO2 recovery plants for application in a wide variety of industries.

MHIENG is proud to introduce an advance, commercially available CO2 recovery process; the Kansai Mitsubishi Carbon Dioxide Recovery Process (KM CDR Process®) which delivers economic performance for plants of wide ranging capacities. The MHIENG CO2 recovery process utilizes "KS-1™ solvent", an advanced hindered amine solvent, in conjunction with a line of special proprietary equipment. The technology was developed through cooperation between MHIENG and Kansai Electric Power Company, Inc. (Kansai). The process is based on an advanced and proven technology for recovering CO2 from various sources of flue gas. Users who adopt this economical process will enjoy benefits such as lower energy consumption, lower solvent degradation and low corrosion.

High Performance

  • Significantly reduced utility costs
  • Simplified operation and maintenance

Large Scale" or "Wide Range in Capacity

Operating experience Maximum Capacity 450 metric T/D (ton per day)

India
Bahrain

Basic design 3,000 metric T/D / Single-train (Ready for delivery)

Wide range of flue gas sources
  • Gas firing
  • Oil firing
  • Coal firing

Process Flow

Flow of the Standard Process

The flue gas blower feeds flue gas from the plant stack to the KM CDR Process®. After cooling in the flue gas cooler to a temperature of 45 degrees centigrade or lower, the flue gas is fed into the bottom section of the absorber and upward through the packing material inside the tower. As the flue gas passes through the material, the KS-1™ solvent is distributed evenly from the top of the absorber onto the packing material, allowing the solvent to selectively capture the CO2 from the gas. Next, the KS-1™ solvent with the captured CO2, "CO2-rich solution", is collected in the bottom section of the absorber, heat exchanged, and pumped into the stripper from the upper section. Once within the stripper, the CO2-rich solution is distributed onto a strip of internal packing placed in contact with an upward stream of stripping-steam produced by the reboiler. This steam strips the CO2 from the CO2-rich solution at the stripper, yielding CO2 with a high purity of 99.9 vol. percent or more at 1.6 barA (Dry Base). At the final stage, the stripped lean solution is cooled down and reintroduced into the absorber through the heat exchanger and cooler.

Process Improvement

Process Features

Unique concept to utilize lean solvent and steam condensate heat for regeneration inside the stripper.

Performance & Improvement
  • Steam Consumption
    1.30 Tons Steam/Ton CO2
    (660 Kcal/Kg. CO2: Expected)
    Note: Steam = 3 Bar G. Saturated
  • Regeneration Energy less than 700 Kcal/Kg.
    CO2 can be guaranteed.

The "Improved KM CDR Process" consumes 15 percent less than the conventional KM CDR Process».

Application for Recovered CO2

EOR (Enhanced Oil Recovery)

CO2 is a highly effective media for enhanced oil recovery. When injected and mixed into crude oil, CO2 and crude oil form a miscible condition thus enhancing its flow ability in the oil layer. Increased flow ability improves the productivity and recovery ratio of crude oil. The use of CO2 EOR with the CO2 recovered from the flue gas of industrial plants is an efficient way to prevent global warming and reinforce energy security at the same time. The figure below indicates a typical industrial scale CO2 EOR operation.

CO2 Geological Sequestration

Geological sequestration projects are being carried out in several countries. The recovered CO2 from flue gas is stored in deep saline aquifers about 1000 meters below the surface of the ground. Various large scale coal fired flue gas CO2 capture and sequestration projects are being developed and will on-stream around 2012-2015.

Chemical Use - UREA Production

Merit
  • Maximize Urea Production
  • Minimum Reconstruction
  • Reduced CO2 Emissions

Chemical Use - Methanol Production

The carbon/hydrogen ratio is adjusted for optimum methanol synthesis by introducing CO2 into the process from the reformer or boiler flue gas, thereby increasing the production of methanol. This process has five important merits:

  • Increased Methanol Production
  • Minimum Reconstruction
  • No Reformer Reconstruction
  • A Reduced Rate of Natural Gas Consumption
  • Reduced CO2 Emission

Others

Dry Ice, Welding, Etc.

CO2 Re-use Presentation

Large-Scale Plant

Conceptual "Large-Scale Plant" Design Study

MHI has developed large-scale CO2 recovery plants based on its proven experience and technologies. MHI has recently completed a basic design package for a 3,000 metric T/D (ton per day) -single train. The package is now ready for delivery on demand under full commercial arrangements.

Gas Boiler
CO2 Capture Plant
3,000 metric T/D (300MW)
Gas Boiler
CO2 Capture & Compression Plant
3,000 metric T/D (400MW)

Commercial Experiences

Malaysia : Kedah

CO2 Recovery Plant in Malaysia

Plant Outline
Client Petronas Fertilizer(Kedah) Sdn Bhd
Location Kedah Darul Aman, Malaysia
CO2 recovery capacity 160 metric T/D (Max. 200 metric T/D)
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea production
Start of operation October 1999
Flue gas source Natural gas fired steam reformer flue gas

Process Description

CO2 is recovered from natural gas fired boiler and heavy oil fired boiler flue gases. Flue gas is cooled and SOx is removed (When CO2 is recovered from heavy oil fired boiler) before entering CO2 absorber.

Japan : Fukuoka

CO2 Recovery Plant in Japan

Plant Outline
Client 'A' chemical company
Location Fukuoka, Japan
CO2 recovery capacity 283 metric T/D (Max. 330 metric T/D)
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 General use (Several Industries)
Start of operation October 2005
Flue gas source Natural gas and heavy oil fired boiler flue gas

Process Description

CO2 is recovered from steam reformer flue gas. CO2 is compressed and then used for urea synthesis. Flue gas is cooled before entering CO2 absorber. This is the MHI's first commercial experience.

India : Aonla

CO2 Recovery Plant in India

Plant Outline
Plant Outline
Client Indian Farmers Fertiliser Co-Operative Ltd.
Location Aonla, India
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation December 2006
Flue gas source Natural gas fired steam reformer flue gas

Process Description

CO2 is recovered from steam reformer flue gas. CO2 is compressed and then used for urea synthesis. Flue gas is cooled before entering CO2 absorber. This is the MHI's first commercial experience.

India : Phulpur

CO2 Recovery Plant in India

Plant Outline
Plant Outline
Client Indian Farmers Fertiliser Co-Operative Ltd.
Location Phulpur, India
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation December 2006
Flue gas source Natural gas fired steam reformer flue gas

India : Kakinada

CO2 Recovery Plant in India

Plant Outline
Client Nagarjuna Fertilizers and Chemicals Limited
Location Kakinada, India
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation March 2009
Flue gas source Natural gas fired steam reformer flue gas

India : Vijaipur

CO2 Recovery Plant in India

Plant Outline
Plant Outline
Client National Fertilizers Limited
Location Vijaipur, India
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation June 2012
Flue gas source Natural gas fired steam reformer flue gas

UAE : Abu Dhabi

CO2 Recovery Plant in Abu Dhabi

Plant Outline
Client Nagarjuna Fertilizers and Chemicals Limited
Location Kakinada, India
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation March 2009
Flue gas source Natural gas fired steam reformer flue gas

Bahrain : Bahrain

CO2 Recovery Plant in Bahrain

Plant Outline
Client Gulf Petrochemical Industries Co.
Location Bahrain
CO2 recovery capacity 450 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation December 2009
Flue gas source Natural gas fired steam reformer flue gas

Pakistan : Ghotoki

CO2 Recovery Plant in Ghotoki

Plant Outline
Client Engro Fertilizers Limited
Location District Ghotoki, Pakistan
CO2 recovery capacity 340 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation 2011
Flue gas source Natural gas fired steam reformer flue gas

Vietnam : Phu My

CO2 Recovery Plant in Vietnam

Plant Outline
Client Petrovietnam Fertilizer and Chemicals Corporation
Location Phu My, Vietnam
CO2 recovery capacity 240 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation 2010
Flue gas source Natural gas fired steam reformer flue gas

Process Description

CO2 is recovered from steam reformer flue gas. CO2 is compressed and then used for urea synthesis. Flue gas is cooled before entering CO2 absorber. This is the MHI's first commercial experience.

Coal Fired Demonstration Experiences

Coal Fired Demonstration Plant in U.S.A : Alabama

Plant Outline

Client Southern Company
Location Plant Barry power Station, Alabama, US
CO2 recovery capacity 500 metric T/D
Process Improved KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Transport and storage (Geo Sequestration)
Start of operation 2011
Flue gas source Coal-fired boiler flue gas

Objectives

CO2 is recovered from a slip stream of flue gas from the Plant Barry Power Station. Following CO2 recovery from the flue gas, the CO2 is compressed and dehydrated before being transported to a near by oil field, by pipeline, for injection and permanent storage in a geological storage formation deep underground.

Coal Fired Demonstration Plant in Japan : Nagasaki

Plant Outline
Client Petrovietnam Fertilizer and Chemicals Corporation
Location Phu My, Vietnam
CO2 recovery capacity 240 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Use of CO2 Urea Production
Start of operation 2010
Flue gas source Natural gas fired steam reformer flue gas

Objectives

CO2 is recovered from a slip stream of flue gas from the Plant Barry Power Station. Following CO2 recovery from the flue gas, the CO2 is compressed and dehydrated before being transported to a near by oil field, by pipeline, for injection and permanent storage in a geological storage formation deep underground.

Demonstration Plant in Japan

Location J-POWER Matsushima Power Station, Nagasaki, Japan
CO2 recovery capacity 10 metric T/D
Process KM CDR Process®
Solvent KS-1™ Solvent
Start of operation July 2006
Flue gas source Coal-fired boiler flue gas 

Results

  • Increased understanding of the effects of impurities on the system (dust,SOx,NOx,etc.)
  • Identifying and incorporating countermeasures for each impurity.
  • Approximately 6,000 hours of operation and experience.
  • Test results will facilitate scale up CO2 capture for coal fired boilers.
  • Proven application of Mitsubishi Heavy Industries Engineering (MHIENG)'s CO2 capture technology for coal fired flue gas steams.

R and D, Pilot Plant and Engineering Head Quarters

JAPAN (Nanko)

Outline of Pilot Plants

Name of plant Multi pollutant test facility
Location Mihara, Japan
Flue gas flow rate 1,200,000 Nm3/hr (400 MWe)
Flue gas source Synethtic flue gas
Start up 2004

Description for blind people

The Nanko pilot plant has a CO2 recovery capacity of 2 metric tons per day and commenced operation in 2004. It is located at the Nanko Power Station near Osaka and operated by Kansai Electric Power Company (KEPCO). The plant has been used to develop and test a variety of solvents and processes resulting in many improvements which have since been commercialized. The CO2 is captured from a natural gas fired boiler.

JAPAN (Mihara)

Outline of Pilot Plants

Name of plant Multi pollutant test facility
Location Mihara, Japan
Flue gas flow rate 1,200,000 Nm3/hr (400 MWe)
Flue gas source Synethtic flue gas
Start up 2004

Description for blind people

The Mihara multi pollutant test facility has an absorber flue gas flow rate of 1,200,000 Nm3/hr or 400MW equivalent and has been used to test both MHI's FGD and CO2 recovery technology following commenced of operation in 2004. It is located at the Mihara R&D Center and operated by Mitsubishi Heavy Industries, Ltd. This plant has been used for large scale CO2 absorber tests using commercial scale liquid distributors.

JAPAN (Hiroshima)

Outline of Pilot Plants

Test Facility Outline
Location Hiroshima, Japan
CO2 recovery capacity 1 metric T/D
Solvent KS-1TM Solvent
Flue gas source Coal fired kettle boiler
Start up 2004

Description for blind people

The Hiroshima pilot plant has a CO2 recovery capacity of 2 metric tons per day and commenced operation in 2004. It is located at the Hiroshima R&D Center and operated by Mitsubishi Heavy Industries, Ltd. The CO2 is captured from a small coal fired kettle boiler.

Engineering Head Quarters

Yokohama Engineering Head Quarters

Mitsubishijuko Yokohama Bldg., 3-1, Minatomirai 3-chome, Nishi-ku, Yokohama, Kanagawa, 220-8401, Japan

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