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Telephone: (201) 267-8670
www.modularprocess.com
Carbon Capture from
Power Plant Flue Gas
KMPS Whitepaper Series
M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I ...
M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I ...
M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I ...
M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I ...
M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I ...
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Case Study: Carbon Capture from
Power Plant Flue Gas
Stan Lam, P.E. | Process Engineering Manager
www.linkedin.com/in/s...
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Case Study: Carbon Capture from Power Plant Flue Gas

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Koch Modular engineering team helped the client design a modular pilot plant system as a significant part of the first ever operating carbon capture and storage facility. The system was installed at a pulverized coal-fueled power plant where the captured CO2 was injected underground for permanent storage. The process boasts high CO2 removal rates, low solvent slip (release) and high CO2 purity.

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Case Study: Carbon Capture from Power Plant Flue Gas

  1. 1. Telephone: (201) 267-8670 www.modularprocess.com Carbon Capture from Power Plant Flue Gas KMPS Whitepaper Series
  2. 2. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 2 Case Study: Carbon Capture Project Koch Modular engineering team helped the client design a modular pilot plant system as a significant part of the first ever operating carbon capture and storage facility. The system was installed at a pulverized coal- fueled power plant where the captured CO2 was injected underground for permanent storage. The process boasts high CO2 removal rates, low solvent slip (release) and high CO2 purity.  CLIENT: A Major Construction and Technology Company.  INDUSTRY: Power Plant Construction
  3. 3. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 3 Key Engineering Features  KMPS was selected as the supplier because of its successful experience in carbon dioxide removal and the capability of designing modular units.  As a test unit, the system was designed to accommodate a broad range of operating conditions.  Modular design allowed for the customer to concentrate on the balance of the greenfield project’s engineering, infrastructure and on-site construction activities, with minimal interruption.  KMPS’s modular system was the earliest to be completed at the site and required minimum site labor.
  4. 4. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 4 Core Challenges  The solvent had a tendency to form solids at low temperatures and in stagnant spots. Proper temperature control and piping design to avoid pockets are essential.  Materials of construction – certain high temperature areas required the use of higher alloys than regular stainless steel.  Installation – most of the column packing and internals were installed in the KMPS shop but the random packing and internals had to be installed on site. A KMPS engineer was on-site to ensure proper installation.  Schedule – the project was schedule-driven. The use of KMPS modules substantially reduced the site labor requirement and shortened project schedule.
  5. 5. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 5 The Solution  Multi-module flue gas carbon capture system including solvent regeneration and recovery.  Based on the client’s “Chilled Ammonia Process”.  The process first absorbs the CO2 using an ammonium carbonate solvent. The CO2 was then stripped out from the solvent in a regenerator, converting the ammonium bicarbonate back into ammonium carbonate. The latter is returned to the CO2 absorber, thus completing the solvent cycle.
  6. 6. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 6 Flue Gas Return -90% CO2 Flue Gas Feed With CO2 Wash Water CO2 CO2Removal& SolventRegeneration CO2Absorber Solvent Cooling Heat Recovery Lean Solvent Rich Solvent CO2 Removal Basic Process Flow Diagram
  7. 7. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 7 Installed Modular Process System
  8. 8. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 8 Impact 1. Because of KMPS’ previous experience with similar projects, Koch Modular was able to capture the special design features to ensure smooth operation of the unit. 2. When the same customer needed a partner to build a larger carbon capture unit in a West Virginia power plant, Koch Modular was the logical choice. 3. Despite the complexity of the equipment, the Koch Modular unit was the most trouble-free section of the plant. 4. The pilot unit was run by the power utility for two years to test the concept – up to 300 tons a day of CO2 was compressed, injected and sequestered between layers of rock deep underground. The project was deemed a complete success.
  9. 9. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 9 Why Modular from KMPS? For this project, KMPS leveraged its extensive CO2 removal experience, proprietary distributor design technology and experience designing modular process systems which resulted in a complete multi-module flue gas carbon capture system including solvent regeneration and recovery that was supplied with a Process Performance Guarantee. Our modular fabrication approach to process systems has many advantages, the main points of which are highlighted below. To learn specifically how modular fabrication achieves these benefits, please visit our website: www.modularprocess.com  Shorter schedule / faster time to market  Lower cost / lump sum bid / single source  Minimal plant site interruption / improved safety
  10. 10. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G Telephone: (201) 267-8670 www.modularprocess.com 10 Koch Modular Products & Services Customer Inquiry Data Startup Assistance and Training Process Development (In Collaboration with Client’s Engineers and Scientists) Material Balance, PFD’s, Unit Operation Selection, Process Simulation Process Design Equipment Design, P&ID’s, Equipment General Arrangement Detailed Engineering Equipment, Piping, Structural, Electrical, Instrumentation & Controls Construction Modular System Specialists in Process Design and Construction of Modular Mass Transfer Systems for the Chemical Processing Industry. Pilot Plant Testing (If Required) 4
  11. 11. 11 Case Study: Carbon Capture from Power Plant Flue Gas Stan Lam, P.E. | Process Engineering Manager www.linkedin.com/in/stan-lam Stan Lam is an expert in the design and troubleshooting of distillation columns. Stan has been designing, inspecting and installing distillation column trays, packing and internals for over 35 years. Stan is a graduate of The University of Birmingham and a certified Professional Engineer.

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