CO₂ Recovery Device for Natural Gas Boiler Exhaust
It is supplied as skid-mounted or modular units for direct integration into new or existing industrial boiler plants.
Introduction
This CO₂ recovery system extracts, separates, and purifies carbon dioxide from post-combustion exhaust produced by natural gas-fired industrial boilers and power generation units.
It is supplied as skid-mounted or modular units for direct integration into new or existing industrial boiler plants.
CO₂ Recovery Performance
CO₂ Capture Rate: 85% to 92% under rated operating conditions.
Inlet Flue Gas CO₂ Concentration Range: 4.0 vol.% to 9.5 vol.% (dry basis).
Recovery Performance Under Turn-Down: Maintains ≥ 80% capture rate between 50% and 110% of rated flue gas flow.
Design Operating Point: Optimized for 8.0 vol.% CO₂ flue gas concentration at 40°C absorber inlet temperature.
Operating Availability: Designed for up to 8,000 operating hours per year, subject to scheduled maintenance and site operating conditions.
Guaranteed Performance Tolerance: ±2 percentage points at the specified design operating point.
Compatibility
Applicable Boiler Types: Fire-tube boilers, water-tube industrial boilers, combined heat and power (CHP) heat recovery steam generators (HRSGs), and thermal oil heaters.
Compatible Boiler Output: 2 MW to 50 MW equivalent thermal input per capture train; larger boiler capacities can be served by multiple parallel trains.
Flue Gas Inlet Temperature Range: 120°C to 220°C (before pretreatment quenching).
Fuel Compatibility: Pipeline natural gas, liquefied natural gas (LNG), and treated coalbed methane (CBM).
CO₂ Product Purity & Output Specifications
|
Parameter |
Industrial Standard Grade |
High-Purity Grade |
|
CO₂ Concentration |
≥ 99.5% |
≥ 99.99% |
|
Oxygen (O₂) |
≤ 0.5 vol.% |
≤ 10 ppm (via catalytic O₂ removal) |
|
Moisture / Dew Point |
Pressure dew point ≤ -40°C |
Moisture ≤ 10 ppm; pressure dew point ≤ -60°C |
|
Carbon Monoxide (CO) |
≤ 20 ppm |
≤ 5 ppm |
|
Total Hydrocarbons (as CH₄) |
≤ 50 ppm |
≤ 20 ppm |
|
Nitrogen & Argon (N₂ + Ar) |
≤ 0.45% |
≤ 100 ppm |
|
Other Trace Impurities |
≤ 0.05% |
≤ 5 ppm |
|
Delivery Pressure |
1.5 MPa to 2.5 MPa (Gas) |
2.0 MPa at -20°C (Liquid) |
CO₂ Capture Process
Primary Separation Technology: Thermally regenerable chemical solvent absorption process optimized for low-partial-pressure post-combustion exhaust.
Overall Process Sequence: Pretreatment → CO₂ Absorption → Solvent Regeneration → CO₂ Compression & Dehydration → Product Gas/Liquid Distribution.
Capture Rate Basis: Calculated from the difference between CO₂ entering and leaving the capture system, based on measured flue gas flow and CO₂ concentration.
Solvent Regeneration Method: Low-pressure steam reboiler supplies heat to strip bound CO₂ at 115°C–122°C.
Energy Consumption & Pressure Drop
Thermal Energy Consumption (Reboiler Duty): 2.8 to 3.4 GJ per tonne of CO₂ recovered (supplied via low-pressure saturated steam at 0.2 MPa–0.3 MPa).
Specific Electrical Energy Consumption: 110 kWh to 160 kWh per tonne of liquid CO₂ (Basis: includes flue gas booster fan, solvent circulating pumps, cooling pumps, CO₂ compression, dehydration, and liquefaction refrigeration).
Flue Gas System Pressure Drop: Total pressure differential across flue gas circuit (pretreatment + absorber) is 2.5 kPa to 4.0 kPa.
Process Makeup Water: 0.1 to 0.3 m³ per tonne of CO₂ (dependent on flue gas inlet temperature and humidity).
Boiler Integration & Retrofit Requirements
Tie-in Point: Exhaust duct connection downstream of boiler economizer/air preheater and upstream of existing stack.
Bypass Damper System: Automated, fast-acting dual-louver bypass damper with mechanical interlock ensures unimpeded boiler exhaust to the stack during CO₂ system startup or trip.
Safe Boiler Bypass: The bypass system maintains the boiler exhaust path independently of the CO₂ recovery unit during startup, shutdown, maintenance, or emergency trip conditions (CO₂ system failure does not cause boiler shutdown).
Booster Blower Integration: Variable Frequency Drive (VFD) controlled booster fan maintains neutral pressure (0 Pa to -50 Pa) at the boiler tie-in point.
FAQ
Q: What warranty and support are provided?
A: The standard warranty is 12 months after commissioning or 18 months after shipment, whichever comes first. Solvent and catalyst are excluded as consumables. Support includes 24/7 remote monitoring and on-site engineers within 7 days when required.
Q: Should I produce gaseous or liquid CO₂?
A: Liquid CO₂ is suitable for storage, transport, beverage production, and food freezing. Gaseous CO₂ at 1.5–2.5 MPa is better suited to nearby pipeline users such as greenhouses.
Q: How much CO₂ can be recovered?
A: A natural-gas boiler produces approximately 0.2 tons of CO₂ per MWh of thermal input. A 10 MW boiler can generate about 48 tons/day and recover approximately 41–44 tons/day at an 85%–92% capture rate.
Q: Can the recovered CO₂ meet beverage-grade requirements?
A: With activated-carbon polishing, CO₂ purity of ≥99.99% can meet applicable ISBT or EIGA beverage requirements.
Q: How much solvent is consumed?
A: Amine solvent consumption is typically 0.3–0.8 kg per ton of CO₂. With reclaimer operation, a full solvent charge generally lasts 2–4 years.
Q: What emissions and waste are generated?
A: With a water-wash section, treated flue gas typically contains less than 5 mg/Nm³ of amine emissions. Reclaimer waste is approximately 0.5–2 kg per ton of CO₂.
Q: How is performance verified?
A: A 72-hour performance guarantee test verifies capture rate, product purity, steam consumption, and power consumption using calibrated meters and CO₂ analyzers. Buyer or third-party witnessing can be arranged.
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