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Estimation and Capturing CO 2 from Emirates Cement Factories

United Arab Emirates University College of Engineering Chemical Engineering Department Training and Graduation Project Units Graduation Project II. Estimation and Capturing CO 2 from Emirates Cement Factories.

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Estimation and Capturing CO 2 from Emirates Cement Factories

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  1. United Arab Emirates University College of Engineering Chemical Engineering Department Training and Graduation Project Units Graduation Project II Estimation and Capturing CO2 from Emirates Cement Factories Project Code CHF2-4 Presenting to :Dr. Ali Al Naqbi , Dr. NayefGhasem Prof. MamdouhGhannam Department Advisor: Dr. Samir Abu-Eishah

  2. Agenda • Acknowledgement. • Introduction. • Summary of Achievements in GPI. • Selection and discussion of final process. • Detailed equipment design. • Design Alternatives. • Details of Cost Analysis & Discussion. • Relevant Codes of Ethics and Moral Frameworks.

  3. Agenda • Codes of Ethics. • Environmental Impact of the Process. • HAZOP (Hazard and Operability). • General loop of the process. • P&ID diagram for the process. • Problem faces and solutions. • Conclusion.

  4. Acknowledgement • We would like to express deepest thanks and appreciation to Dr. Samir Abu-Eishah, the supervisor of the graduation project for his leadership and supervision, also would like to express our sincere appreciation to the college coordinator, Dr. Hend Al-Qamzi, for her guidance during our presentations. • We would like to thank chemical engineering professors and special thanks go to the Training and Graduation Projects Unit.

  5. Introduction • Problem statement: • Cement industry is responsible for about 5% of the global emission of the CO2 to atmosphere. • The purpose of this project is to estimate and capture CO2 from the stacks of the Emirates Cement Factories in Al Ain. • Project and design objective: • Find the best techno-economical solution to capture CO2 from the Emirate Cement Factories.

  6. Introduction • Outcomes and Deliverables: • The system was a physical absorption process using Selexol as a solvent to capture CO2. • The equipment were designed based on the process operating conditions. • The system control loop was identified for safety and HAZOP consideration. • HAZOP study of equipments was determined for different situations. • Cost analysis was made based on CAPCOST estimations and annual operating cost .

  7. Summary of Achievements in GPI • The linkage system was selected to connect flue gases from Emirate Cement Factories to our process. • The flue gas was cooled and the water accompanning the flue gas was separated. • The flue gas was then compressed and cooled before entering the absorber. Figure 1: Linkage system in GPI drawn by khulood Al jaberi

  8. Summary of achievement in GPI • Selected process in GPI: • The process selected in GPI was chemical solvent absorption using (MEA), which is the most suitable method for capturing CO2 from other gases for low CO2 concentrations. • The flue gases from ECF enter a packed absorption column. The counter current flow was used with the chemical solvent for more efficient absorption of CO2 by chemical reaction. • For energy integration ,Rich solvent from the absorber exchanges its heat with the lean solvent from the stripper through a heat exchanger. • CO2 is separated from the rich solvent in a stripper using a reboiler. • The lean solvent is recycled back to the absorber and CO2 was sent to storage

  9. Flow sheet Figure2 :Chemical absorption with MEA solvent drawn by Elham Abdullah

  10. Summary of achievement in GPI • Material balance: • Two sources of CO2: • Combustion of Natural gas: CO2= 15.65 (ton/hr) • Calcinations of carbonates, for example, calcium carbonate: • Amount of CO2 produced from calcinations: • From limestone 9.65 (ton/hr) • From marl stone 4.72 (ton/hr)

  11. Summary of achievement in GPI Rotary Kiln Figure3:Material balance around the rotary kiln drawn by khulood Al jaberi

  12. Summary of achievement in GPI • Energy balance: • Energy balance was around the E-100 which cooled the flue gases and water from 150oC to 40oC. • E-100 divided into three zones: Figure4: three phases in heat exchanger drawn by EimanSaleh

  13. Summary of achievement in GPI • Water: • Gas:

  14. Selection and discussion of final process • The linkage system was modified by replacing the separator by heat exchanger with boot which collects the condensed water. • Multi stage compressor with three inter cooling was added. Figure5 : Multi stage compressor flow sheet drawn by khuloodSaeed

  15. Selection and discussion of final process • Physical absorption process was selected for this project . • The Final design consists of six coolers, one multi stage compressor, one heat exchanger, one pump, one absorber, one flash separator and one vessel. Figure 6: Process flow sheet drawn by ElhamAbdullah and EimanSaleh

  16. Selection and discussion of final process • Process optimization: • Temperature • Pressure

  17. Selection and discussion of final process • Liquid flow to gas flow ratio (L/G) • Number of Trays

  18. Detailed equipment design • Pump P-100 (power required) • Compressor K-100 (power required) • Heat exchanger E-105 ( Overall heat transfer, Area) • Flash drum V-100 (diameter , height) • Absorber T-100 (diameter , height)

  19. Pump P-100 design • The required information for calculating pump power is as follows: • Based on rules of thumb the applicable equation is:

  20. Pump P-100 design • Centrifugal multistage pumps are usually used for the volumetric flow rate of 0.076 - 41.6 m3/min. • since the system volumetric flow rate 40.48 within the range the required efficiency is 0.75. • Required power:

  21. Compressor K-100 design • Input for compressor power calculation: • Large centrifugal compressors are at the range of 2.83 – 47.2 m3/s. • since the system flow rate is within this range then the efficiency is 0.75.

  22. Compressor K-100 design • Required power:

  23. Heat exchanger E-105 design • The split ring floating head exchanger was chosen because for efficiency and ease of cleaning. Figure7: split ring floating heat exchanger Reference: http://omranenergy.com/index.php?option=com_content&view=article&id=35&Itemid=27

  24. Heat exchanger E-105design • Step 1: Specification definitions

  25. Heat exchanger E-105design • Step 2: Overall heat transfer coefficient and heat transfer area

  26. Heat exchanger E-105design • Assuming overall heat transfer coefficient after different trails the U assumed to be 1600W/m2.oC, then • The procedure outlined in (book) was followed for the estimation for the final heat transfer area for the heat exchanger as shown below:

  27. Flash V-100 design

  28. Flash calculation

  29. Absorber T-100 design: For absorber design two things must be found the diameter and the height of the tower. For diameter: = diameter of the tower (m) = volumetric flow rate of gases (m3/s) = velocity of gases (m/s)

  30. Absorber T-100 design: • The velocity ( ) was calculated using: : Vapor density (kg/m3) : Liquid density (kg/m3) : Constant obtained from k was found from figure (8) and using FLV and tray spacing From heuristics for tower calculation the tray spacing is 0.5 (m)

  31. Absorber T-100 design: Figure8: k for sieve plate (Coulson and Richardson, Chemical Engineering Design book , volume 6)

  32. Absorber T-100 design: = 0.07 • Height calculation:

  33. Design Alternatives • There are three alternatives for the system: • CO2 absorption process. • Regeneration of the solvent. • CO2 final product to storage.

  34. Design Alternatives Process alternative: • Chemical Absorption. • Used for low CO2 concentration. • Two absorption columns, or more, in series are needed. • Fresh solvent for each column is needed. • Physical absorption: • Can be used for high concentration

  35. Design Alternatives Regeneration of the solvent: • Flash drum instead of stripper. • No packing or trays. • No reflux. CO2final product to storage: • For high pressure or liquefied CO2. • Add compressor and cooler/condenser. • Store CO2.

  36. Details of Cost Analysis &Discussion • The cost estimation is divided into capital cost and manufacturing cost. • Capital cost estimation is related directly to the operating condition and the equipment size. • Manufacturing costs depends on the fixed capital investment, cost of operating labor, cost of raw materials, cost of utilities and cost of waste treatment.

  37. Details of Cost Analysis and Discussion

  38. Details of Cost Analysis and Discussion

  39. Details of Cost Analysis and Discussion

  40. Details of Cost Analysis and Discussion • Cooling water utility:

  41. Details of Cost Analysis and Discussion • Compressor power requirement:

  42. Details of Cost Analysis and Discussion • Selexol cost: • Selexol cost is equal to 1.32 $/lb, • total amount required = 5,494,000 lb/year.

  43. Details of Cost Analysis and Discussion

  44. Details of Cost Analysis and Discussion • Labor cost:

  45. Details of Cost Analysis and Discussion Profit Calculation

  46. Details of Cost Analysis and Discussion

  47. Details of Cost Analysis and Discussion

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