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Improved technology for carbon capture & storage saves capital cost

Total man-made carbon dioxide (CO2) emissions in the world today amount to approximately 30 Gigatons per year, with fossil fuel-based power stations contributing in excess of 30% of this total. Carbon Capture is an energy intensive process, buy Sulzer’s specialized technology allows the operator to minimize capital expenditures and at the same time, minimize power output losses that can result from poor designs.

High Efficiency Mass Transfer Products Reduce Capital Costs Generally, only structured packing can meet the low pressure drop requirements for the design of the Direct Contact Cooler and the CO2 Absorber. Compared with random packing or trays, structured packing’s significantly lower pressure drop and better mass transfer efficiency make it ideal for these services. The resulting lower column diameters and packed bed heights translate into lower capital expenditure and lower operating costs.

Sulzer’s new MellapakCCTM structured packing absorbs CO2 more efficiently than conventional packings, particularly for post-combustion capture. Compared with MellapakTM 2X structured packing, MellapakCC provides 20% higher efficiency and 20% lower pressure drop. When compared with conventional Mellapak 250.Y structured packing, MellapakCC provides the same efficiency but up to 60% lower pressure drop.

Specialized Structured Packing Excels at Low Liquid Rates
In post-combustion capture, solvent emissions to the atmosphere from the top of the CO2 Absorber must be controlled in order to meet environmental regulations. The make-up water required to reduce the solvent emissions substantially (from ppm down to ppb range) is very low due to the low vapor pressure of most amine solvents. Low water rates result in specific liquid loads of <100 liters/m2hr operating conditions where conventional structured packing shows significantly reduced efficiency. Sulzer has developed a new structured packing, AYPlus™ DC, which shows extraordinary wetting characteristics with aqueous systems. To handle such low liquid rates, a special liquid distributor (VEPK), was also developed. This combination of AYPlus DC structured packing and VEPK liquid distributor dramatically increases the separation performance, thus making it possible to realize “close to zero” solvent emissions at the top of the CO2 absorber.

Unique Technical Challenges Require Experienced Designers
Carbon Capture column diameters can reach 20 meters or more. Poor structural design or internals that cannot properly distribute gas or liquid across an extremely large crosssectional area can create major increases in initial capital cost or serious operating problems. The installation of the vessel internals must be carefully considered to minimize the time and cost of field work. To effectively address the unique challenges related to these mega size columns, an experienced mass transfer engineering company, like Sulzer Chemtech and Sulzer’s Field Services Group, is required.

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Tray designs for extreme fouling applications

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Anti-fouling trays maximize coker main fractionator profitability

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Improve separation in your column by increasing the number of trays

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Gain 5-10% efficiency with this simple 4-pass tray revamp

The design of 4-pass trays can be complex. It not only requires a close evaluation of the mechanical design but also the process response to that design at various flow rates. The balancing of the fluid flows across the tray can have a substantial effect on the tray performance, namely efficiency.

Proper design of mass transfer internals in the FCC flue gas scrubber can help reduce PM emissions

The EPA’s New Source Performance Standards (40 C.F.R. §60.100-1-0, subpart Ja) regulates refinery particulate emissions, including the discharge of catalyst fines from the FCCU flue gas scrubber stack. Because refiners have traditionally correlated particulate matter (PM) emissions with FCCU ...

Improve fouling resistance in your wastewater benzene stripper

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Important tray design features that improve column operating reliability

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Green design practices: focus on efficiency

Green design is more than recycling scrap materials or calculating carbon footprints. It minimizes negative environmental impact through skillful design and operating practices to produce efficient, better-functioning processes. Because green practices reduce resource requirements, in many cases, they ...

4 simple ways to convert turnarounds into profitable tower upgrade opportunities

With planned outages commonly occurring at intervals of 2-5 years, a refinery turnaround is a prime opportunity to replace column and separator internals with the newest available technology. Planning for an outage with a “replacement-in-kind” strategy will address lost performance from refinery ...

Maximizing light cycle oil recovery in the FCC main fractionator

Refiners operating FCCU's have adjusted their operating strategies to maximize light cycle oil production to meet the increased demand for automotive diesel. Catalyst formulations and reactor conditions can alter yields, but the refinery cannot take full advantage of the increased LCO recovery without ...