Analysis and Optimization of ASU for Oxyfuel Combustion

Sichuan Air Separation Plant (Group) Co., Ltd.

Jiang Rong

www.saspg.com
Outline

1 Introduction

2 ASU of SASPG for Oxyfuel Combustion

3 Research of ASU for Oxyfuel Combustion

Page 1
Outline

1 Introduction

Page 1
Introduction
 CO2 emissions by fossil fuel combustion
has accelerated the global warming

 Oxyfuel combustion is one of the most potential

technologies to reduce CO2 emissions for large
scale coal-fired power plant

O2 purity:
above 95%

Analysis
optimization

Reduce Energy
consumption

Page 2
Outline

2 ASU of SASPG for

Oxyfuel Combustion

Page 1
Introduction of SASPG
 Sichuan Air Separation Plant (Group) Co.Ltd (SASPG) is located in Jianyang City,
east to the city of Chengdu, a leading cryogenic plant and equipment manufacturing
company.
Since founded in 1966, SASPG has kept on increasing its operation scales. Up to
2015, the annual production capacity reached 50,000 tons, the total asset of SASPG
reached 3 billion RMB, and has 2500 Employees .
 SASPG consists of 4 branch companies, 17 subsidiaries, 3 research institutes and
holds shares of other 7 enterprises.

第5页
Introduction of SASPG
Product Profile

Air Separation Plants

Natural Gas (Associated Gas) Liquefaction
and Separation Plants
Industry Gases
Cryogenic Liquid tank and tankers
Erection Services
Turbo-expander
Plate-fin Heat Exchangers
Vacuum Insulated Piping
Cryogenic Pumps
Cryogenic valves
 Medical Machinery, Medical Equipment
第6页
Introduction of SASPG
Fabrication Facility

SASPG New Facility in Hangzhou

10m Vacuum Brazing Furnace 第7页 Automatic fin cleaning machine

ASU of SASPG for Oxyfuel Combustion

3MWth Full Chain Oxyfuel Combustion Pilot System (HUST)

Air separation unit(ASU)and CO2 compression

and purification Unit(CPU) are sponsored by
SASPG.(about 15 million yuan)

Construction period: From Feb.2011 to Dec.

2011

ASU
Capacity: 600Nm3/h
Conventional double-column distillation
system

CO2 Compression and Purification Unit

 Capacity: 600Nm3/h

SASPG obtain patents on ASU for oxyfuel

combustion and CPU.
Page 3
ASU of SASPG for Oxyfuel Combustion

35MWth Oxyfuel Combustion Industrial

Demonstration System(Yingcheng)
SASPG undertake the subject-----Research and
Demonstration of new ASU for Oxyfuel Combustion

ASU investment partly from project funding and partly

sponsored by SASPG (about 13 million yuan)

ASU parameters:
Capacity: 6400Nm3/h
GOX Purity: 97.5%
GOX Pressure:50kPa.G
New three-column distillation system

 ASU construction completed in June 2015, and started

to operation in July 2015
Page 4
ASU of SASPG for Oxyfuel Combustion
Flowsheet of ASU

Page 5
ASU of SASPG for Oxyfuel Combustion
Key1: Oxygen purity : 97.5%

Normal ASU oxygen purity is 99.6% with conventional double-column distillation system

New three-column distillation system used for oxygen purity 97.5% , decrease energy

consumption by 8%~10% compared with normal ASU

 high pressure column(4.2barG),

medium pressure column(2.6barG)

low pressure column(0.3barG)

 air compressor :

32000Nm3/h/0.98barG, 7000Nm3/h/2.8barG,25000Nm3/h/5.5barG

Page 6
ASU of SASPG for Oxyfuel Combustion

Key2: Oxygen pressure: 50kPa.G

LOX self-pressurization process

LOX pressure is increased through height difference between the main

condenser and LOX evaporator, the pressurized LOX is vaporized in LOX

evaporator and reheated in main heat exchanger

Cancel the oxygen compressor, energy saving and more safety

Page 6
ASU of SASPG for Oxyfuel Combustion
Key3: Vertical radial flow purifier

Vertical radial-flow purifier:

Lower pressure drop of air and waste

nitrogen

Better air distribution

Smaller cover area

Vertical radial Horizontal

flow purifier purifier

Pressure drop 3~4kpa 7kpa

Cover area 25% 1

Energy -1% 1
consumption
Page 6
ASU of SASPG for Oxyfuel Combustion
Commission and Operation of ASU

The commissioning of ASU started in July 21, 2015

The oxygen product reached design value in July 24,2015

Oxygen purity, oxygen pressure and energy consumption have reached the design value

capacity

purity

第14页
Outline

3 Research of ASU for

Oxyfuel Combustion

Page 1
Research of ASU for Oxyfuel Combustion

ASU for 200MWe oxyfuel combustion system

SASPG signed R&D contact of ASU

for 200MWe oxyfuel combustion system
with Shenhua Guohua(Beijing) Electric
Power Research Institute Co. in June
2014.

ASU Requirements:

ASU Capacity: 2 × 60000 Nm3/h

GOX Purity: 95~99.6%

GOX Pressure: 50 kPa.G

Page 8
Research of ASU for Oxyfuel Combustion
Key1: R&D of ASU process

Page 9
Research of ASU for Oxyfuel Combustion
Key1: R&D of ASU process

Page 10
Research of ASU for Oxyfuel Combustion
Key1: R&D of ASU process

Type of processes
Two columns process Three columns process
Equipments
First stage Capacity：
299000 Nm3/h
Inlet/outlet pressure:
Capacity：290000 Nm3/h 0.095/0.325MPa(A)
Air compressor Inlet/outlet pressure：
0.095/0.535 MPa(A) Second stage Capacity：
158500 Nm3/h
Inlet/outlet pressure:
0.325/0.535 MPa(A)

One air cooling tower and two air cooling tower and
Cooling system
one water cooling tower one water cooling tower

One set of purification Two sets of purification system

Purification system system (with two purifiers (with four purifiers and two steam
and one steam heater) heaters)

Page 11
Research of ASU for Oxyfuel Combustion
Key1: R&D of ASU process

Through the comparison of different processes, using HYSYS software simulation and
optimization of different process, we obtained a diagram of ASU energy consumption
with different oxygen concentration, as shown below:

Page 12
Research of ASU for Oxyfuel Combustion
Key1: R&D of ASU process

Conclusions:
With the increase of oxygen purity, energy consumption per unit oxygen
of two processes increased.
When oxygen purity between 0.95 to 0.98, the energy consumption per
unit oxygen of three-column process is 8%~10% lower than two-column
process. So three column process should be used.
When oxygen purity between 0.98 and 0.99,the energy difference
between two processs decrease gradually. So both process can be used
users by considering investment cost and energy consumption
comprehensively.
When oxygen purity higher than 0.99, the investment cost and energy
consumption of three-column process are higher than two-column
process. So two-column process should be used.

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Research of ASU for Oxyfuel Combustion
Key2: R&D of ASU dynamic response

According to the characteristics of oxygen

Oxygen ,
used in power plant: nitrogen Automatic
load change
ASU Load change range:50~105% exchange

Load change rate: no less than 5%/min

Consideration for load change:

Operation cost
Investment cost Liquid
Methods
oxygen of load diffuse
Adjust characteristic
vaporized change

Add liquid Multiple sets

equipment of equipment

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Research of ASU for Oxyfuel Combustion
Key2: R&D of ASU dynamic response

Suggestion:

ASU Load change Range between75~105%, load change rate no more than 1%/min,

automatic load change

ASU Load change Range between 75~105%, load change rate no less than 5%/min,

oxygen-nitrogen exchange and liquid oxygen vaporized

Load change Range between 50~75%, load change rate no more than 1%/min,

automatic load change and oxygen-nitrogen exchange

Load change Range beween 50~75%, load change rate no less than 5%/min, add liquid

equipment and liquid oxygen vaporized

Page 14
Thank you