Preliminary Design Specification
Project Summary
Zhengzhou University
Boyuan Team
2010.10
A CCS&U post-fuel subsystem to produce Poly Propylene Carbonate(PPC)
Project Summary
With the increasing aggravation of global greenhouse effect, to reduce carbon dioxide emission has emerged to be a top priority facing the international sustainable development. Among the industrial carbon dioxide emission, the exaust gas emitted from coal-fired power plant takes up a considerable proportion; therefore the technique for carbom dioxide capture, storage, and utilization (CCS&U) from coal-fired power plant exhaust has become an international hot research field. This project is a CCS&U post-fuel subsystem; with the backing of Zhengzhou XinLi Power Co., Ltd. It adopts chemical absorption process to capture carbon dioxide, which is then combined with propylene oxide as raw materials to synthesize Poly Propylene Carbonate (PPC), a kind of degradable plastic. In this way this project attains the objective of carbon dioxide reutilization.
Process introduction
I. Process in capture phase
Figure 1 CO2 capture process
The flue gas discharged from the furnaces of power plant is compressed in the air blower, and then sent into the cooling tower to cool down. Whereafter, an amount of the high pressure normal-temp gas at the cooling tower’s gas vent is absorbed by the absorbing tower, leaving the unabsorbed gas discharged from the tower upper. After being compressed by pump and heat transfered, the rich solution is then sent into the analytic tower. Then the vapor-contained CO2, which is discharged from the gas vent of the analytic tower upper, goes through a process of liquid-vapor separation in the flash tank. Through these procedures, CO2 with high-purity is obtained. Meanwhile after being compressed and heat transferred, the lean solution is re-used in the absorbing tower.
BoYuan Team
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A CCS&U post-fuel subsystem to produce Poly Propylene Carbonate(PPC)
II.process in utilization phase
Figure 2 CO2 utilization process
Under the protection of nitrogen, epoxide is added to the pre-dried high pressure reaction cauldron, and then in-let carbon dioxide to undergo polymerization. Carbon dioxide copolymer is produced as the outcome of the reaction. Throughout the reaction process, a hydro-and-oxygen-free environment is required and the raw materials need desiccation, so the polymerization is implemented after a strict detection of the reaction condition.
At the termination of the reaction, the generated carbon dioxide copolymer is collected into the recycling cauldron, while the surplus propylene oxide and carbon dioxide is recovered into the recycling tank or gasometer. Then the copolymer will be diced with water-ring dicing cutter and then cleansed to go through a sequence of desiccation, extrusion, pelleting, and packaging treatments. Ultimately, CO2-based fully degradable plastic masterbatch is obtained.
III.Plant site selection
This plant is well-located in Zhengzhou central plains district in Henan province, backed by Zhengzhou XinLi Power Co., Ltd. Several factors can account for the site selection.
√ The good environmental conditions and well-equipped production and living facilities in central plains district
√ Abundance in natural and land resources and an adequate supply of labor √ A scientific industrial planning and a good basis for industrial development √ Convenience in transportation and logistics
BoYuan Team
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A CCS&U post-fuel subsystem to produce Poly Propylene Carbonate(PPC)
Plant and workshop layout
A detailed plant and workshop arrangment design has been carried out according to the requirement in the project blueprint. With the help of AutoCAD, Google SketchUp and other software, two-dimensional and three-dimensional plant simulations are worked out respectively. (See diagram 3 and 4) The plant is divided into five districts, namely administration, residency, production, production subsidiary, and storage district. This plant design is made strictly in accordance with relevant criterions in “Regulations of Construction Design for Fireproof” (GBJ16-1987，2001 ), and “Regulations of Oil Companies Design for Fireproof (GB50160-1992，1999).
Figure3 plant plane view drawing
BoYuan Team
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A CCS&U post-fuel subsystem to produce Poly Propylene Carbonate(PPC)
Figure 4 plant three-dimensional view drawing
Economic Appraisal
Through a computation of the fixed assets investment, design and construction cost and other expenses, a total investment cost accounting is worked out as shown in Table 1.
Table 1 cost accounting
Serial No. Unit Category of Cost Consumption per Ton variable cost monoethanolamine Propylene oxide electricity Others
Unit Price Totle Sum (yuan/t) 16475.2 30.2 8376 69 8000
BoYuan Team
I 1 2 3 5
2.75(Kg/t) 11000(yuan/t) 698(Kg/t) 12000(yuan/t) 115(KWH) 0.6(yuan/KWH) （catalyst, water）
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A CCS&U post-fuel subsystem to produce Poly Propylene Carbonate(PPC)
II 1 2 Constant cost wage for labors loan interest Depreciation of fixed assets Management expense others Unforeseeable cost Factory cost Sales expense Marketing cost 5,000,000,000yuan (annual rate 5.4%) 819.8 9.3 308.2 3 4 5 6 3.3 172.6 120 200 17288.6 1500 18788.6 III IV V Hereby the marketing cost is acounted as 20,000 yuan/t.
The final product of this project is degradable plastic whose unit price is 25,000yuan/t, and the annual output 876,000 tons. Taken into account of the taxes and other costs, the annual net profit turns out to be 2,171,000,000 yuan. The static investment payback period is one year and a half.
Conclusion
This project presentation includes the design instruction (feasibility analysis report included), the core equipment, a buleprint for the layout of the plant and workshops, as well as an optimized design and simulation carried out follow Aspen Plus technical process. Through a detailed computation, the carbon dioxide collection efficiency exceeds 80%, which meets the design requirement. What’s more, by generating degradable plastics, this project effectively realizes the objective of carbon dioxide reutilization. Technical and economic appraisal proves this project a great benefit to society and economy.
BoYuan Team
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