Tackling increased CO2 concentration in feeds for existing acid gas removal units: A simulation study based on a customized CO2 kinetics model

A Middle East-based amine sweetening unit, with an overall capacity of about 2.2 BSCFD of gas, is among the world’s largest process plants and currently processes sour gas with 10 mol% of hydrogen sulfide (H₂S) and carbon dioxide (CO₂) put together. Current expectation is that acid gas contents in the feed may increase beyond the design limit of the plant. The present work is an effort to quantify the effects of the feed gas CO₂ increase on the plant and to proffer solutions to handle these effects efficiently. We revised the kinetics of amine-based CO₂ absorption correlation of an existing model using real-data-driven parameters re-estimation. Evolutionary technique that employs particle swarm optimization algorithm is used for this purpose. The new CO₂ kinetic model is inserted in a first-principle process simulator, ProMax® V4.0, in order to analyze various solutions necessary to mitigate the operational challenges due to increased feed CO₂. The process plant with present design and operating conditions is determined to handle up to 8.45 mol% CO₂ contents in the sour gas feed. Further results revealed that methyldiethanolamine, diethanolamine, and dimethyl ether propylene glycol (DEPG) could not handle this high feed CO₂ challenge, even at maximum (design) steam and solvent usage. However, diglycolamine exclusively renders the solution as it treats high CO₂ feed gas efficiently with allowable utility consumption, while satisfying the constraints imposed by product gas specifications.     

Hybrid FSC membrane for CO2 removal from natural gas: Experimental,process simulation,and economic feasibility analysis

The novel fixed‐site‐carrier (FSC) membranes were prepared by coating carbon nanotubes reinforced polyvinylamine/polyvinyl alcohol selective layer on top of ultrafiltration polysulfone support. Small pilot‐scale modules with membrane area of 110–330 cm² were tested with high pressure permeation rig. The prepared hybrid FSC membranes show high CO₂ permeance of 0.084–0.218 m³ (STP)/(m² h bar) with CO₂/CH₄ selectivity of 17.9–34.7 at different feed pressures up to 40 bar for a 10% CO₂ feed gas. Operating parameters of feed pressure, flow rate, and CO₂ concentration were found to significantly influence membrane performance. HYSYS simulation integrated with ChemBrane and cost estimation was conducted to evaluate techno‐economic feasibility of a membrane process for natural gas (NG) sweetening. Simulation results indicated that the developed FSC membranes could be a promising candidate for CO₂ removal from low CO₂ concentration (10%) NGs with a low NG sweetening cost of 5.73E?3 $/Nm³ sweet NG produced. © 2014 American Institute of Chemical Engineers AIChE J 60: 4174–4184, 2014     

Cu/ZnO/AlOOH catalyst for methanol synthesis through CO<Subscript>2</Subscript> hydrogenation

Catalytic conversion of CO₂ to methanol is gaining attention as a promising route to using carbon dioxide as a new carbon feedstock. AlOOH supported copper-based methanol synthesis catalyst was investigated for direct hydrogenation of CO₂ to methanol. The bare AlOOH catalyst support was found to have increased adsorption capacity of CO₂ compared to conventional Al₂O₃ support by CO₂ temperature-programmed desorption (TPD) and FT-IR analysis. The catalytic activity measurement was carried out in a fixed bed reactor at 523 K, 30 atm and GHSV 6,000 hr^?1 with the feed gas of CO₂/H₂ ratio of 1/3. The surface basicity of the AlOOH supported Cu-based catalysts increased linearly according to the amount of AlOOH. The optimum catalyst composition was found to be Cu : Zn : Al=40 : 30 : 30 at%. A decrease of methanol productivity was observed by further increasing the amount of AlOOH due to the limitation of hydrogenation rate on Cu sites. The AlOOH supported catalyst with optimum catalyst compositions was slightly more active than the conventional Al₂O₃ supported Cu-based catalyst.     

SELECTIVE GAS ABSORPTION UNDER PRESSURE

For selective removal of H2S from much larger quantities of CO₂ under pressure, an industrial prototype spray column has been constructed. Sodium hydroxide solution was atomized by a pressure nozzle of special design and entered the scrubber as fine spray to contact the sour gases.

Several operating variables were examined in order to indicate optimal operating conditions for maximum selectivity of H₂S over CO₂. Fine mist and short contact time favor this selective absorption process. An optimum inlet reactant concentration was found dependent upon the H₂S content relative to CO₂ in the inlet sour gas mixture. A special nozzle/shield configuration to avoid contact of sour gas with highly turbulent liquid during droplet formation significantly improved the selectivity.     

Oxidation of low concentrations of hydrogen sulphide: Process optimization and kinetic studies

Low concentrations (e.g. < 3) of H₂ S in natural gas can be selectively oxidized over an “granular Hydrodarco” activated carbon catalyst to elemental sulphur, water and a small fraction of by-product sulphur dioxide, SO₂. To optimize the H₂ S catalytic oxidation process, the process was conducted in the temperature range 125—200 °C, at pressures 230—3200 kPa, with the O/H₂ S ratio being varied from 1.05 to 1.20 and using different types of sour and acid gases as feed. The optimum temperature was determined to be approximately 175 °C for high H₂ S conversion and low SO₂ production with an O/H₂ S ratio 1.05 times the stoichiometric ratio. The life of the activated carbon catalyst has been extended by removing heavy hydrocarbons from the feed gas. The process has been performed at elevated pressures to increase H₂ S conversion, to maintain it for a longer period and to minimize SO₂ production. The process is not impeded by water vapour up to 10 mol% in the feed gas containing low concentrations of CO₂ (< 1.0). A decrease in H₂ S conversion and an increase in SO₂ production were obtained with an increase in water vapour in the feed gas containing a high percentage of CO₂. The process works well with “sour natural gas” containing approximately 1% H₂ S and with “acid gas” containing both H₂ S and CO₂. It gives somewhat higher H₂ S conversion and low SO₂ production with feed gas containing low concentrations of CO₂. A kinetics study to determine the rate-controlling step for the H₂ S catalytic oxidation reaction over “granular Hydrodarco” activated carbon has been conducted. It was concluded that either adsorption of O₂ or H₂ S from the bulk phase onto the catalyst surface is the rate-controlling step of the H₂ S catalytic oxidation reaction.     

Equilibrium solubility of CO<Subscript>2</Subscript> in aqueous binary mixture of 2-(diethylamine)ethanol and 1, 6-hexamethyldiamine

CO₂ solubility data are important for the efficient design and operation of the acid gas CO₂ capture process using aqueous amine mixture. 2-(Diethylamino)ethanol (DEEA) solvent can be manufactured from renewable sources like agricultural products/residue, and 1,6-hexamethyldiamine (HMDA) solvents have higher absorption capacity as well as reaction rate with CO₂ than conventional amine-based solvents. The equilibrium solubility of CO₂ into aqueous binary mixture of DEEA and HMDA was investigated in the temperature range of 303.13-333.13 K and inlet CO₂ partial pressure in the range of 10.133-20.265 kPa. Total concentration of aqueous amine mixtures in the range of 1.0-3.0 kmol/m³ and mole fraction of HMDA in total amine mixture in the range of 0.05-0.20 were taken in this work. CO₂ absorption experiment was performed using semi-batch operated laboratory scale bubble column to measure equilibrium solubility of CO₂ in amine mixture, and CO₂ absorbed amount in saturated carbonated amine mixture was analyzed by precipitation-titration method using BaCl₂. Maximum equilibrium CO₂ solubility in aqueous amine mixture was observed at 0.2 of HMDA mole fraction in total amine mixture with 1.0 kmol/m³ total amine concentration. New solubility data of CO₂ in DEEA+HMDA aqueous mixtures in the current study was compared with solubility data available in previous studies conducted by various researchers. The study shows that the new absorbent as a mixture of DEEA+HMDA is feasible for CO₂ removal from coal-fired power plant stack gas streams.     

Kinetic study on carbonation of crude Li<Subscript>2</Subscript>CO<Subscript>3</Subscript> with CO<Subscript>2</Subscript>-water solutions in a slurry bubble column reactor

Investigations were conducted to purify crude Li₂CO₃ via direct carbonation with CO₂-water solutions at atmospheric pressure. The experiments were carried out in a slurry bubble column reactor with 0.05 m inner diameter and 1.0 m height. Parameters that may affect the dissolution of Li₂CO₃ in the CO₂-water solutions such as CO₂-bubble perforation diameter, CO₂ partial pressure, CO₂ gas flow rate, Li₂CO₃ particle size, solid concentration in the slurry, reaction temperature, slurry height in the column and so on were investigated. It was found that the increases of CO₂ partial pressure, and CO₂ flow rate were favorable to the dissolution of Li₂CO₃, which had the opposite effects with Li₂CO₃ particle size, solid concentration, slurry height in the column and temperature. On the other hand, in order to get insight into the mechanism of the refining process, reaction kinetics was studied. The results showed that the kinetics of the carbonation process can be properly represented by 1−3(1−X)^2/3+2(1–X)=kt+b, and the rate-determining step of this process under the conditions studied was product layer diffusion. Finally, the apparent activation energy of the carbonation reaction was obtained by calculation. This study will provide theoretical basis for the reactor design and the optimization of the process operation.     

Solvent extraction of uranium from acidic sulfate media by Alamine® 336: computer simulation and optimization of the flow‐sheets

BACKGROUND: A series of nine conventional and non‐conventional flow‐sheets have been considered for the recovery of uranium from acidic sulfate solution by liquid–liquid extraction with 0.146 mol L^?1 Alamine^® 336 in kerosene modified with 5% w/w 1‐tridecanol and stripping with a 199 g L^?1 Na₂CO₃ solution. The reference flow‐sheet was a classical counter‐current configuration with four mixers–settlers in the extraction stage and three mixers–settlers in the stripping stage. The others flow‐sheets possessing a total of eight mixers–settlers are unusual combined solvent extraction flow‐sheets with one or two independent extraction stripping loops and with one or two feed inlets. RESULTS: The configuration of the flow‐sheets strongly influences the extraction performance of the process depending on the working conditions (feed, stripping and solvent flow rates). The presence of two independent extraction–stripping loops may allow the delay of the saturation phenomenon encountered in the conventional flow‐sheet and thus, to operate at higher feed flow rates without loss of performance, as far as the residual fraction in the raffinate and the concentration factor in the stripping solution are concerned. Furthermore, the presence of a modification in the non‐conventional flow‐sheets with two independent extraction–stripping loops and two feed inlets leads to interesting configurations for uranium recovery from less concentrated solutions, such as heap leach solutions. CONCLUSION: The use of non‐conventional flow‐sheets is interesting as it allows the process of uranium (VI) recovery by liquid–liquid extraction to be improved. Copyright © 2009 Society of Chemical Industry     

Parametric study of pyrolysis and steam gasification of rice straw in presence of K<Subscript>2</Subscript>CO<Subscript>3</Subscript>

A parametric study of pyrolysis and steam gasification of rice straw (RS) was performed to investigate the effect of the presence of K₂CO₃ on the behavior of gas evolution, gas component distribution, pyrolysis/gasification reactivity, the quality and volume of synthetic gas. During pyrolysis, with the increase in K₂CO₃ content in RS (i) the instantaneous CO₂ concentration was increased while CO concentration was relatively stable; (ii) the yield of CO₂ and H₂ increased on the cost of CH₄. During steam gasification of RS, with the increase in K₂CO₃ content in RS (i) the instantaneous concentration of CO₂ and H₂ increased while instantaneous concentration of CO and CH₄ decreased; (ii) the yield of CO₂ and H₂ production and total yield increased; and (iii) yield of CO and CH₄ production followed the order: 9% K₂CO₃ RS<6% K₂CO₃ RS<raw RS<3% K₂CO₃ RS<water-leached RS. Water-leached RS showed the highest pyrolysis reactivity, while stream gasification reactivity was proportional to K₂CO₃ content in RS. The results of this study reveal that the presence of K₂CO₃ during pyrolysis and steam gasification of RS effectively improves production of H₂ rich gas.     

Solvent selection for CO<Subscript>2</Subscript> capture from gases with high carbon dioxide concentration

Amine absorption processes are widely used to purify both refinery and process gases and natural gas. Recently, amine absorption has also been considered for application to CO₂ removal from flue gases. It has a number of advantages, but there is one major disadvantage-high energy consumption. This can be solved by using an appropriate solvent. From a group of several dozen solutions, seven amine solvents based on primary amine, tertiary amine and sterically hindered amine were selected. For the selected solutions research was conducted on CO₂ absorption capacity, an absorption rate and finally a solvent vapor pressure. Furthermore, tests on an absorber-desorber system were also performed. In this study the most appropriate solvent for capturing CO₂ from flue gases with higher carbon dioxide concentrations was selected.     

Improvement in steam stripping of sour water through an industrial-scale simulation

Sour water containing hydrogen sulfide, carbon dioxide, hydrogen cyanide, and ammonia is mainly purified by steam stripping. Increased concern in recent times over effluent water quality and energy saving has caused sour water stripping to attract considerable attention. However, the development of the operation methodology and structure of this process has not been systemic, leading to inefficiencies in the systems commonly used. In this paper, the characteristics of a sour water stripping column are investigated by using an industrial-scale simulation. From these results, we propose several guidelines (high feed temperature, low composition of CO₂ in the feed, need of rectifying section, low mass flow rate of the second recycle stream, high reflux ratio, and modified structure using a pump-around side cooler) for improving stripper performance through changes in the operating condition and process structure. The proposed structure and guidelines can be applied not only to reduce steam consumption and lower the ammonia concentration in the effluent water but also to operate the system stably.     

Effects of pressure and temperature on fixed-site carrier membrane for CO<Subscript>2</Subscript> separation from natural gas

In this paper, the effect of testing temperature on the performance of fixed carrier membrane for CO₂ separation were studied. The blend composite membranes were developed respectively with a blend of PEI-PVA (polyetheleneimine-polyvinyl alcohol) as separation layer and PS (polysulfone) ultrafiltration membranes as the substrates. The permselectivity of the membranes was measured with CO₂/CH₄ mixed gas. The effect of testing temperature on membrane separation performance was investigated. The results showed that both the permeances of CO₂ and CH₄ decreased with the increase of temperature, and the permeances decreased more quickly under low pressure than those under high pressure. At the feed pressure of 0.11 MPa, the CO₂/ CH₄ selectivity of PEI-PVA/PS blend composite membrane reduced along with temperature increment. Under the feed pressure of 0.21 MPa, as well as 1.11 MPa, the selectivity decreased with the increase of temperature.     

Carbon dioxide absorption into biphasic amine solvent with solvent loss reduction

The main challenge in the CO₂ capture from flue gases is to reduce the energy consumption required for solvent regeneration. Lipophilic amines exhibit a thermomorphic phase transition upon heating, giving rise to autoextractive behaviour, which enhances desorption at temperatures well below the solvent boiling point. The low regeneration temperature of less than 80 °C together with the high cyclic CO₂ loading capacity (c. 0.9 mol-CO₂/mol-absorbent) of such biphasic amine systems permit the use of low temperature and even waste heat for desorption purposes. In order to improve the capture process and reduce the commensurate energy demand still further, desorption experiments were carried out at 70-80 °C and techniques for enhancing CO₂ release without gas stripping were also studied. The comparison of various amines at a concentration of 3 M and for a 15 mol% CO₂ feed gas demonstrates the considerable potential of lipophilic amines for the CO₂ absorption process. Chemical stability is a decisive factor for the industrial application of amine absorbents. Degradation of the novel lipophilic amine absorbents was shown to be minor, while volatility losses represent a major shortcoming of the biphasic solvent systems. Appropriate countermeasures to limit solvent losses were examined experimentally.     

Natural gas sweetening using low temperature distillation: simulation and configuration

ABSTRACT

Hypothesis: Separation of CO₂ from a stream of natural gas using low-temperature distillation process is complicated not only because of the existence of ethane (C₂) and CO₂ azeotrope but owing to the freezing of CO₂. A modified process based on an existing Ryan–Holmes process in the form of a low-temperature distillation is presented here for the separation of sour gases. In addition, solvents were employed to prevent CO₂ freezing and to avoid formation of the C₂-CO₂ azeotrope.

Simulation: Simulation calculations were carried out using a natural gas stream containing CO₂ and H₂S. The process was designed and simulated using Aspen HYSYS 9.

Findings: A low-temperature process for the separation of a feed stream containing up to 30 mole% CO₂ and 2.5 mole% H₂S was achieved, which lowered the levels of these gases to within 50 and 4 ppm, respectively. These values conform to liquefied natural gas specifications. The compositions of the product streams, the required solvent circulation flow rates, and the total energy requirements were estimated. The reported process successfully separated H₂S and produced CO₂ at a pressure of 25.0 bar and a temperature of ?13°C, thereby ensuring its suitability for application in enhanced oil recovery. This described process also delivered the desired natural gas product at 35 bar and ?90°C ready for liquefaction and further cooling.     

Sorption studies of CO<Subscript>2</Subscript>, CH<Subscript>4</Subscript>, N<Subscript>2</Subscript>, CO,O<Subscript>2</Subscript> and Ar on nanoporous aluminum terephthalate [MIL-53(Al)]

Aluminum terephthalate, MIL-53(Al), metal–organic framework synthesized hydrothermally and purified by solvent extraction method was used as an adsorbent for gas adsorption studies. The synthesized MIL-53(Al) was characterized by powder X-Ray diffraction analysis, surface area measurement using N₂ adsorption–desorption at 77 K, FTIR spectroscopy and thermo gravimetric analysis. Adsorption isotherms of CO₂, CH₄, CO, N₂, O₂ and Ar were measured at 288 and 303 K. The absolute adsorption capacity was found in the order CO₂>CH₄>CO>N₂>Ar>O₂. Henry’s constants, heat of adsorption in the low pressure region and adsorption selectivities for the adsorbate gases were calculated from their adsorption isotherms. The high selectivity and low heat of adsorption for CO₂ suggests that MIL-53(Al) is a potential adsorbent material for the separation of CO₂ from gas mixtures. The high selectivity for CH₄ over O₂ and its low heat of adsorption suggests that MIL-53(Al) could also be a compatible adsorbent for the separation of methane from methane–oxygen gas mixtures.     

Characterization of the permeation properties of CO2N2 gas mixtures in silicone rubber membranes

The separation characteristics of silicone rubber membranes are determined for CO₂N₂ gas mixtures. The analysis is performed as a function of composition, flow rate and pressure of the feed gas. Results are presented in terms of the variation in component permeability and separation factor as a function of the above parameters. Component permeabilities are calculated using the complete mixing model. Data analysis over the studied pressure range shows that the permeability coefficient of pure CO₂ gas in silicone rubber is 15 times higher than that of pure N₂ gas. This behaviour is completely altered for a mixture of the gases, where the calculated separation factors at low feed pressures and low CO₂ mole fractions in the feed stream are two- to three-fold lower than the separation factors for the pure gases. At higher feed pressures and high CO₂ mole fractions in the feed stream, the above behaviour is reversed; the separation factors for the gas mixture are now higher than those for the pure gases. Comparison of the permeation characteristics of silicone rubber and cellulose acetate membranes for CO₂N₂ gas mixtures shows similar ranges and values for the gas permeabilities and separation factors. However, much higher separation factors are obtained for the cellulose acetate membrane in the case of pure gas permeation.     

Sorption-enhanced dimethyl ether synthesis—Multiscale reactor modeling

As an opportunity for the attenuation of atmospheric CO₂ emissions, conversion of carbon dioxide into valuable oxygenates as fuel additives or fuel surrogates was explored conceptually in terms of a potentially feasible dimethyl ether (DME) conversion process. Incentives for application of conventional CO₂–DME conversion process are insufficient due to low CO₂ conversion, and DME yield and selectivity. In-situ H₂O removal by adsorption (sorption-enhanced reaction process) can lead to the displacement of the water gas shift equilibrium and therefore, the enhancement of CO₂ conversion into methanol and the improvement of DME productivity. A two-scale, isothermal, unsteady-state model has been developed to evaluate the performance of a sorption-enhanced DME synthesis reactor. Modeling results show that under H₂O removal conditions, methanol and DME yields and DME selectivity are favoured and the methanol selectivity decreases. The increase of methanol and DME yields and DME selectivity becomes more important at higher CO₂ feed concentration because a relatively large amount of water is produced followed by a large quantity of water removed from the system. Also, the drop in the fraction of unconverted methanol becomes more important when CO₂ feed concentration is higher and the dehydration reaction is favoured. Therefore, application of the sorption-enhanced reaction concept allows the use of CO₂ as a constituent of the synthesis gas as the in-situ H₂O removal accelerates the reverse water gas shift reaction.     

High speed spin coating in fabrication of Pebax 1657 based mixed matrix membrane filled with ultra-porous ZIF-8 particles for CO<Subscript>2</Subscript>/CH<Subscript>4</Subscript> separation

Modified ultra-porous ZIF-8 particles were used to prepare novel ZIF-8/Pebax 1657 mixed matrix membranes (MMMs) on PES support for separation of CO₂ from CH₄ using spin coating method. TEM and SEM were used to characterize modified ZIF-8 particles. SEM was also used to investigate the morphology of synthesized MMMs. The MMMs with thinner selective layer showed higher CO₂ permeability and lower CO₂/CH₄ selectivity in permeation tests compared to MMMs with thicker selective layer. The plasticization was recognized as the main reason for rise in CO₂ permeability and drop in CO₂/CH₄ selectivity of thinner MMMs. The gas sorption results showed that the high permeability of CO₂ in MMMs is mainly due to the high solubility of this gas in MMMs, leading to high CO₂/CH₄ solubility selectivity for MMMs. The fractional free volume and void volume fraction of MMMs increased as the thickness of membrane decreased. Applying higher mixed feed pressures and permeation tests temperatures resulted in increase in CO₂ permeability and decrease in CO₂/CH₄ selectivity. At highest testing temperature (60 °C), the CO₂ permeability of synthesized MMMs with thinner selective layer remarkably increased.     

Understanding the performance of membrane for direct air capture of CO2

Direct air capture (DAC) of CO₂ is becoming increasingly important for reducing greenhouse gas concentrations in the atmosphere. However, the cost and energy requirements associated with DAC make it less economically feasible than carbon capture from flue gases. While various methods like solid sorbents and gas–liquid absorption have been explored for DAC, membrane processes have only recently been investigated. The objective of this study is to examine the separation performance of a membrane unit for capturing CO₂ from ambient air. The performance of a membrane depends on several factors, including the composition of the feed gas, pressure ratio, material selectivity, and membrane area. The single-stage separation process with the co-current flow and constant permeability flux model is evaluated using a commercial module integrated with a process simulator to separate a binary mixture of carbon dioxide and nitrogen to assess the sensitivity of selectivity on purity and recovery of CO₂ in permeate, and power requirement. Additionally, three levels of CO₂ reduction from the feed stream to the retentate stream (25%, 50%, and 75%) are studied. A trade-off between purity and recovery factor is observed, and achieving high purity in permeate requires high concentration in the retentate.