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WEC Italia – Cattura e Stoccaggio della CO 2  (CCS) Roma, October 18, 2011 Technologies for Carbon Capture  in Oil Refineries Ivano Miracca Saipem s.p.a.
Saipem Highlights Leading Global EP(I)C General Contractor ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Saipem Experience on  Carbon Capture and Sequestration (CCS)   SAIPEM has substantial know-how and experience in the entire CO 2  capture, transportation and storage chain acquired providing engineering services to Eni and other O&G companies .  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Storage : Capture : ,[object Object],[object Object],[object Object],[object Object],Transportation : Source Source
Presentation Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Power Station vs. Refinery
A sense of scale ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Different issues and concerns Plot plan availabilty is a  key concern Plot plan availability is not necessarily a concern Additional safety issues mainly related to use of pure oxygen Additional safety issues mainly related to use of chemicals Already includes process units using the same techniques than capture units CO 2  capture introduces new types of processes inside the power station Capture operation of the same type than usual refinery operation Very fast and drastic changes in workload may be required CO 2  Concentration variable with source and feedstock Fixed CO 2  Concentration (4% for NGCC – 12% for coal) Multiple sources  (20 or more stacks ) Single Source REFINERY POWER STATION
Refinery Emission Sources
Emissions vary for different crudes and refineries Source: ExxonMobil (2008) GHG emissions: > 4.8 MTPY GHG emissions: < 1.2 MTPY Hydrogen production No Hydrogen production Many Heaters & Boilers (> 50) Few Heaters & Boilers (< 12) Fuel: Fuel Oil Fuel: Natural Gas Complex refinery with many different products No cracking – No sulfur reduction 100,000 BPSD HEAVY CRUDE 100,000 BPSD LIGHT CRUDE HIGH EMISSION REFINERY LOW EMISSION REFINERY
Refinery Carbon Sources SMR Heaters Co-Gen FCC Regen Fuel Reformer Feed Flue Gas Flue Gas Flue Gas Flue Gas Air Two major emitters ,[object Object],[object Object],[object Object],[object Object],Power Steam
Typical distributions of emissions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
CO 2  Capture in the FCC unit
Overview of an FCC unit RISER ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Steam Air REGENERATOR Flue gas   10 – 20 % CO 2 A unit processing 60,000 bpsd emits  ~ 1,000,000 t/year of CO2
Main technological options A – Waste Heat Boiler B – SOx scrubber C – Amine Unit D – CO2 compressor E – Dehydration (mol. sieve) F – ASU G – Recycle compressor Equipment list > 99% pure 90% recovery 96% pure >99 % recovery Flue-gas A B C D E Amine Absorption CO2 Flue-gas A B F D E G 99.5% O2 Oxy-combustion CO2 Recycle
Some comparison among options ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],The CCP Oxy-combustion FCC Demonstration Run
CO 2  Capture in hydrogen production
Steam Methane Reforming SMR Water Gas  Shift H 2  Purification (PSA) Natural Gas Flue Gas ~ 765 kg CO 2 / 1000 Ncu ft H 2 Feed Fuel Steam ,[object Object],[object Object],[object Object],[object Object],Air Tail gas Product
Autothermal Reforming ,[object Object],[object Object],[object Object],[object Object],Syngas generation Water-gas shift CO2 removal Fuel H 2 , CO CO 2 , H 2 O H 2 , CO 2 H 2 CO 2 H 2 O O 2 H 2 O Air Separation Air N 2
CO 2  Capture in process heaters & boilers
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Heaters & Boilers: a peculiar source of CO 2
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Capture techniques applied to Heaters & Boilers
Overall approach to carbon capture  in the refinery
The Hydrogen-fired refinery Heaters Co-Gen FCC Regen Air Power Steam ATR Water-gas shift CO2 removal Fuel H 2 , CO CO 2 , H 2 O H 2 , CO 2 CO 2 H 2 O O 2 H 2 O Air Separation Air N 2 Flue Gas Hydrogen CO2-free gas to stack To hydrotreating
[object Object],[object Object],[object Object],[object Object],[object Object],Current limitations to an hydrogen-fired refinery
The Oxygen-fired refinery SMR Heaters Co-Gen FCC Regen Fuel Reformer Feed Power Steam ASU Air Nitrogen Oxygen Flue gas O 2 Flue gas CPU CO 2 Flue gas
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Current limitations to an oxygen-fired refinery
The Complete Environmental Services Provider THANK YOU FOR YOUR ATTENTION

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Technologies for Carbon Capture in Oil Refineries

  • 1. WEC Italia – Cattura e Stoccaggio della CO 2 (CCS) Roma, October 18, 2011 Technologies for Carbon Capture in Oil Refineries Ivano Miracca Saipem s.p.a.
  • 2.
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  • 5. Power Station vs. Refinery
  • 6.
  • 7. Different issues and concerns Plot plan availabilty is a key concern Plot plan availability is not necessarily a concern Additional safety issues mainly related to use of pure oxygen Additional safety issues mainly related to use of chemicals Already includes process units using the same techniques than capture units CO 2 capture introduces new types of processes inside the power station Capture operation of the same type than usual refinery operation Very fast and drastic changes in workload may be required CO 2 Concentration variable with source and feedstock Fixed CO 2 Concentration (4% for NGCC – 12% for coal) Multiple sources (20 or more stacks ) Single Source REFINERY POWER STATION
  • 9. Emissions vary for different crudes and refineries Source: ExxonMobil (2008) GHG emissions: > 4.8 MTPY GHG emissions: < 1.2 MTPY Hydrogen production No Hydrogen production Many Heaters & Boilers (> 50) Few Heaters & Boilers (< 12) Fuel: Fuel Oil Fuel: Natural Gas Complex refinery with many different products No cracking – No sulfur reduction 100,000 BPSD HEAVY CRUDE 100,000 BPSD LIGHT CRUDE HIGH EMISSION REFINERY LOW EMISSION REFINERY
  • 10.
  • 11.
  • 12. CO 2 Capture in the FCC unit
  • 13.
  • 14. Main technological options A – Waste Heat Boiler B – SOx scrubber C – Amine Unit D – CO2 compressor E – Dehydration (mol. sieve) F – ASU G – Recycle compressor Equipment list > 99% pure 90% recovery 96% pure >99 % recovery Flue-gas A B C D E Amine Absorption CO2 Flue-gas A B F D E G 99.5% O2 Oxy-combustion CO2 Recycle
  • 15.
  • 16.
  • 17. CO 2 Capture in hydrogen production
  • 18.
  • 19.
  • 20. CO 2 Capture in process heaters & boilers
  • 21.
  • 22.
  • 23. Overall approach to carbon capture in the refinery
  • 24. The Hydrogen-fired refinery Heaters Co-Gen FCC Regen Air Power Steam ATR Water-gas shift CO2 removal Fuel H 2 , CO CO 2 , H 2 O H 2 , CO 2 CO 2 H 2 O O 2 H 2 O Air Separation Air N 2 Flue Gas Hydrogen CO2-free gas to stack To hydrotreating
  • 25.
  • 26. The Oxygen-fired refinery SMR Heaters Co-Gen FCC Regen Fuel Reformer Feed Power Steam ASU Air Nitrogen Oxygen Flue gas O 2 Flue gas CPU CO 2 Flue gas
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  • 28. The Complete Environmental Services Provider THANK YOU FOR YOUR ATTENTION