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Clean Techn Environ Policy

DOI 10.1007/s10098-014-0787-7

ORIGINAL PAPER

Modeling and simulation of high pressure water scrubbing


technology applied for biogas upgrading
Petronela Cozma • Walter Wukovits •
Ioan Mămăligă • Anton Friedl • Maria Gavrilescu

Received: 12 September 2013 / Accepted: 12 May 2014


Ó Springer-Verlag Berlin Heidelberg 2014

Abstract Depending on the end of use, the quality of on the removal of undesired components from biogas were
biogas must be upgraded in order to utilize the maximum examined, based on modeling and simulation tools. For
amount of energy necessary for proper applications. simulation, the commercial software tool Aspen Plus was
Upgrading biogas refers to the increase of methane con- applied. Equilibrium model was applied for simulating the
centration in product gas by removal of CO2, which absorption process. The simulation results were validated
increases its heating power. Several treatment technologies with experimental data from the literature. The results are
are available for biogas upgrading: high pressure water summarized in terms of system efficiency, expressed as
scrubbing (HPWS), pressure swing adsorption, membrane CH4 enrichment, methane loss, and CO2 removal. Finally,
separation, chemical absorption, and gas permeation. Water new data which can be further applied for scale-up calcu-
absorption based on the physical effect of dissolving gases lations and techno-economic analysis of the HPWS process
in liquids (HPWS) is a well-known technology and the most are provided.
effective upgrading process, since provides a simultaneous
removal of CO2 and H2S. This could ensure an increasing Keywords Biogas upgrading  CO2 removal efficiency 
methane concentration and energy content per unit volume Gas absorption  Gas solubility  High pressure water
of biogas. In spite of this, few studies are published on scrubbing  Process simulation
biogas upgrading using pressurized water technology. In
order to elucidate the performance of HPWS technology at Abbreviations
industrial scale with the possibility of water regeneration AFR Air flow rate, Nm3/h
and recirculation, effects of different operating parameters CH4Recirc CH4 recirculated from flash back to crude
biogas (%)
CO2Recirc CO2 recirculated from flash back to crude
P. Cozma  M. Gavrilescu (&)
Department of Environmental Engineering and Management, biogas (%)
‘‘Gheorghe Asachi’’ Technical University of Iasi, 73 Prof. dr. CO2 RE CO2 removal efficiency (%)
doc. D. Mangeron Street, 700050 Iasi, Romania FWFR Fresh water flow rate (m3/h)
e-mail: mgav@ch.tuiasi.ro
GFR Plant capacity/gas flow rate (Nm3/h)
W. Wukovits  A. Friedl G Total gas flow rate (Nm3/h)
Institute of Chemical Engineering, Vienna University of HPWS Water scrubbing technology
Technology, Getreidemarkt 9/166, 1060 Vienna, Austria L Total liquid flow rate (m3/h)
M% Methane losses (%)
I. Mămăligă
Department of Chemical Engineering, ‘‘Gheorghe Asachi’’ Pflash Pressure in flash (bar)
Technical University of Iasi, 73 Prof. dr. doc. D. Mangeron Pstripper Pressure in stripper (desorber) column
Street, 700050 Iasi, Romania (bar)
Pabsorber Pressure in absorber column (bar)
M. Gavrilescu
Academy of Romanian Scientists, 54 Splaiul Independentei, PG Product gas which is equivalent to upgraded
050094 Bucharest, Romania biogas

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P. Cozma et al.

SG Off gas from stripper 2010; Jørgensen and Andersen 2012; Kapdi et al. 2005;
Tabsorber Temperature in absorber column (°C) Petersson and Wellinger 2009; Puksec and Duic 2012).
Tstripper Temperature in stripper (desorber) However, both the biogas composition and the concentra-
column (°C) tions of the contaminants are strongly dependent on the
VWFR/VGFR Volumetric water flow rate to gas flow type of waste or plant type used for the production of
rate ratio (vol-based) biogas and on the season (Bruijstens et al. 2008; Cozma
VFWFR/VGFR Volumetric fresh water flow rate to gas et al. 2013a; Zagorskis et al. 2012). Usually, the CO2 and
flow rate ratio (vol-based) H2S concentration in raw biogas varies from 30 to 50 vol%
VWFR/VWPA Volumetric water flow rate to water and from 10 to 4,000 ppm, respectively. The usage of
pump-around flow rate ratio (vol-based) biogas as a renewable energy source in combined heat and
VWPA/VGFR Volumetric water pump-around flow rate power plants, as a transport vehicle fuel, or as a substitute
to gas flow rate ratio (vol-based) for natural gas has significantly increased in the last years
VAFR/VGFR Volumetric air flow rate to gas flow rate (Kismurtono 2011; Petersson and Wellinger 2009; Petter-
ratio (vol-based) son 2013). Depending on the end of use, the quality of
XCO2 ;p¼10 Concentration of CO2 in liquid phase at biogas must be upgraded in order to increase its heating
the equilibrium pressure of 10 bar value and to meet requirements for some gas appliances
XCO2 ;p¼3 Concentration of CO2 in liquid phase at (engines, boilers, fuel cells, vehicles) (Bauer et al. 2013;
the equilibrium pressure of 10 bar Cozma et al. 2012; Mateescu et al. 2008; Petersson and
YH2S,PG H2S content in product gas (vol%) Wellinger 2009). Upgrading of biogas refers on increasing
YCH4,PG CH4 content in product gas (vol%) methane concentration by removal of CO2 (Andriani et al.
YCH4,SG CH4 content in off gas (vol%) 2014; Cozma et al. 2012; Lems and Dirkse 2010; Starr
WFR Make-up water (% evaporated water per et al. 2012). There are some established technologies
hour of WPA) (m3/h) applied for biogas upgrading based on: adsorption (pres-
WPA Water pump-around flow rate (amount of sure swing adsorption), absorption (pressurized water
recirculated water) (m3/h) wash, physical or chemical absorption), membrane (high
CH4 recirculated ð%Þ pressure, low pressure) separation, cryogenic upgrading
V CH4 REC (Balkenhoff and Jamieson 2008; Cozma et al. 2013a; Heile
¼  100;
VCH4 RICHSOL et al. 2014; Shao et al. 2012).
CO2 recirculated ð%Þ Absorption with water or high pressure water scrubbing
V CO2 REC (HPWS, where pressure is around 10 bar) is one of the most
¼  100;
VCO2 RICHSOL common technique applied in an upgrading biogas plant for
simultaneous removal of CO2 and H2S, due to the lower
where VCH4 REC ; VCO2 REC —CH4 and capital an operational cost implied, being a reliable and a
CO2 mol flow rate (kmol/h) at the top proven technology, simple and easy to maintain, without a
exit of flash (GAS-REC stream; the pre-treatment necessary (only if H2S content is low) (Cozma
stream from flash recirculated back to et al. 2012; Eze and Agbo 2010; Hudde 2010; Kapdi et al.
absorber);VCH4 RICHSOL ; VCO2 REC 2005; Lems and Dirkse 2010; Lombardi and Carnevale
CH4 and CO2 mol flow rate (kmol/h) at 2013; Ofori-Boateng and Kwofie 2009; Rasi et al. 2008).
the bottom exit of the absorber Several studies were carried out on comparative cost analysis
VCH4 OFF GAS
Methane loss ð%Þ ¼  100; of different types of technologies applied for biogas
VCH4 Raw biogas upgrading (Anand et al. 2014; Jönsson 2010; Krich et al.
2005; Lems and Dirkse 2009; Ofori-Boateng and Kwofie
where VCH4 is the CH4 mol flow rate
2009; Scholz et al. 2013; Teghammar et al. 2014). HPWS
(kmol/h); the methane loss is expressed as
was found to be one of the simplest and most economical
% of the outlet stream of stripper (off gas)
methods among the conventional one, such as chemical
and inlet stream of biogas (raw biogas)
absorption, membrane separation, pressurized swing
absorption, or cryogenic separation (Rasi et al. 2014).
However, when water is regenerated in a desorption column,
Introduction the energy consumption and costs are higher compared with
single pass scrubbing (Eze and Agbo 2010). In spite of this,
Most of the biogas is produced during anaerobic digestion HPWS with regeneration of water is recommended to reduce
of organic matter (e.g., manure, vegetable wastes, muni- the amount of fresh water implied in the non-regenerative
cipal solid waste, waste water etc.) (Cornea and Dima HPWS process, since almost 100 times less water can be

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Modeling and simulation of high pressure water scrubbing technology

consumed by a plant regenerating its water (Electrigaz parameters necessary for scaling-up of water scrubbing
Technologies Inc. 2008; Starr et al. 2012). technology.
HPWS provides simultaneous removal of CO2 and H2S In this context, the main objective of the present study
and product gas enrichment with CH4, since CO2 and H2S was to simulate and evaluate the performances of HPWS
are more soluble in water compared with CH4, N2, and O2 technology with regeneration and recirculation of water
(Tippayawong and Thanompongchart 2010). Thus, physi- applied for the removal of pollutants from biogas, in par-
cal absorption of gases in water is governed by Henry’s ticular CO2, and to generate new data for scale-up calcu-
Law, which implies an accurate knowledge of the solubility lations and techno-economic analysis of the process. There
of the main biogas components in water. This is an are two main approaches to modeling absorber and strip-
essential condition for an optimum design and optimization per: equilibrium and rate-based approaches. Only the
of HPWS process (Cozma et al. 2013a). equilibrium-stage approach is used in this study. All the
Although pressurized water scrubbing is a well-devel- simulations were developed by commercial Software tool
oped technology and increasingly implemented, especially Aspen Plus (V.7.1., 2009).
in EU members states, and plants in different sizes are
already commercially available (Cozma et al. 2012; Pet-
ersson and Wellinger 2009), there are few reports on the Solubility of gases in water
related literature on operating and design parameters
affecting the performances of upgraded biogas using this In the present study, the ability of some thermodynamic
technology (Cozma et al. 2013b). In general, plant capac- models to calculate the solubility of the main biogas
ity, the biogas and product gas composition, working components (CO2, CH4, H2S, N2, and O2) in pure water is
pressure, and in some cases make-up water values are the tested using Aspen Plus commercial software tool. The
basic data specified on a biogas upgrading plant (Cozma results are compared with some relevant experimental data
et al. 2012). Gas absorption using HPWS is usually carried from the literature.
out in packed-bed columns due to higher contact surface In our study, we used a single standard flash unit with
area and effective mass and heat transfer provided by dif- varying operation conditions by changing the pressure and
ferent types of packing materials. Packed-bed absorption temperature in the system. In addition, the following
columns present various operational problems like high thermodynamic models were tested: UNIQUAC (with ideal
pressure drop or flooding phenomena (Khan et al. 2011; gas and Henry’s Law), NRTL (non-random-two-liquid/
Sen et al. 2013). In order to achieve high CO2 removal with ideal gas and Henry’s Law), NRTL-RK (non-random-
efficiency and methane enrichment, there is a need for two-liquid/Redlich–Kwong equation of state with Henry’s
improved design of packed-bed absorption column and law), UNIQ-RK (UNIQUAC/Redlich–Kwong equation of
optimization of operating conditions. Moreover, the rapid state with Henry’s Law); ELECNRTL (the electrolytic
increase in energy cost and the need of pollution control non-random two liquids thermodynamic model with the
and waste minimization often require the redesign and Redlich–Kwong equation of state for aqueous and mixed
optimization of an existing process (Bandyopadhyay 2011; solvent applications ? Henry’s law) (Aspen Physical
Gavrilescu 2008; Krallis et al. 2010). Property System 2010; Cozma et al. 2013a).1 The selection
Since there is a lack of models applied for HPWS process of the models are supported by the fact that for the
and important data are not shown, it was considered oppor- absorption condition interests (low to medium pressures
tune to develop simulation studies. These additional studies and temperatures) no special EOS and/or mixing rules nor
will improve the plants functionality and elucidate the main fitting of interaction parameters are necessary to describe
factors that influence the efficiency of the process (Santos the gas solubility (Cozma et al. 2013a).
et al. 2013). In this manner, a basis for further research can be Considering the importance of some gas–water systems
provided. Simulation studies represent efficient way for in the environmental protection, geological science, or
evaluation of different possible conversion processes as well biological field, several experimental measurements have
as to find optimum operation conditions for a given system been made by different authors on the solubility of binary
with respect to economic, safety, and environmental criteria systems of carbon dioxide–water, methane–water, H2S–
(Cozma et al. 2013b; Friedl et al. 1995, 2004). The optimi- water, nitrogen–water, and oxygen–water, over wide ran-
sation of parameters concerning physical absorption process ges of pressures, and temperatures. Moreover, different
is necessary to obtain the maximum CO2 removal with low theoretical models for calculating the solubility of gases in
methane loss at a minimum level of energy demand (Lantela pure water were developed (Cozma et al. 2013a).
et al. 2012). More studies must be developed in order to
provide optimum performance, reliability, and low invest- 1
The paragraph has been adapted from Environmental Engineering
ments costs based on well-established operating and design and Management Journal with permission of the Editor-in-Chief.

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P. Cozma et al.

Fig. 1 Solubility of biogas components in water: a CO2, b CH4, permission of the Editor-in-Chief) (Fig. 1b— literature compilation:
c H2S, d N2, e O2 (adapted upon Cozma et al. 2013a; reproduced from Stoessell and Byrne 1982; Mao et al. 2011)
Environmental Engineering and Management Journal with

Before simulation, a brief analysis regarding the available Before going into details on the results, the following
literature data on solubility of the main biogas components in aspects must be noted:
water was developed (data not shown; for more information
– the calculated data from Fig. 1a are compared with
please see the paper of Cozma et al. 2013a). Based on this
experimental data of Lide (1992);
analysis, the most relevant data were selected for each binary
– the solubility of CH4 in water is calculated using
system (carbon dioxide–water, methane–water, H2S–water,
experimental data of Chapoy (2004) and Chapoy et al.
nitrogen–water, and oxygen–water) and compared with our
(2004) and compared with experimental data of Mao
calculations. The results are plotted in Fig. 1.

123
Table 1 Available literature data on biogas upgrading using HPWS with regeneration of water
Parameters Units Götz et al. Gryta Darmstadt Wixhausen DVGW R&D- DMT TS-PHPWSÒ Henriksdal Most likely
(2011) plant program ‘‘Biogas’’ Technology plant parameters

CH4/CO2 vol% 53.7/45.2 60–75/– 52/47 55.7/42.15 65/– 65/– 55–65/35–45


H2S/H2 ppm 101.8/508 \2,000/– \300/– –/– 1,500/– – 100–2,000
N2/O2/H2/H2O vol% 0.93/0.19 – –/B1/–/–/ 1.85/0.3/–/– – – –
Pabsorber bar 8/(6–17) 10 14 – 8–10 – –
o
Temperature C 20 – – – – – 20
Plant capacity (GFR) Nm3/h 242.3 – – 650 (m3/h) – 1,400 150–2,000
Make-up water (WFR) kg/h – – – – 500–5,000 – 500–5,000
AFR Nm3/h – – – – – – –
WPA m3/h 47.8 – – – – 210 –
Pflash bar 2–4 2–4 – – 2 – 2–4
Pstripper bar 1 – – – 1 – 1
VWFR/VGFR vol-based – – – – 0.002–0.0025 – –
VWPA/VGFR vol-based – – – – – – –
VAFR/VGFR vol-based 2.128/(0.13–0.32) – – – – – –
Results
Modeling and simulation of high pressure water scrubbing technology

CO2 RE [%] 98.96 – – 90.15 – – [97


M% 0.36 \2 0.8–1.8 \2 – \2
3
Treated flow rate Nm /h 133.9 – *150 – – – –
Upgraded biogas – – – – – –
CO2 mole fraction – – B 0.025 0.0415 \0.02 0.02 \0.02
CH4 0.968 [0.97 C0.97 0.916 [0.97 *0.97 C0.97
H2S 1 ppm – 0.7 ppm \1 ppm \3 ppm – \1 ppm
N2 0.021 – 0.033 – 0.01 0.01–0.033
O2 0.0056 – 0.0009 0.0078 – – 0.0009–0.0078
H2 – – – – – – –
H2O 0.0032 – – – – – –
Off gas – – – – – – –
CO2 mole fraction – – – 0.14–0.22 – – –
CH4 0.0007 – – 0.001–0.004 – – 0.0007–0.004
H2S 39.5 ppm – – 20–90 ppm – – 20–90 ppm
N2 0.652 – – 0.62–0.7 – – 0.6–0.7
O2 0.173 – – 0.16–0.19 – – 0.16–0.19
H2 – – – – – – –
H2O – – – – – – –

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P. Cozma et al.

et al. (2011) and Stoessell and Byrne (1982); the of 600 Nm3/h and was later extended to treat a total of
compilation of the last tow references is plotted in the 1,400 Nm3/h raw biogas. This plant improves the biogas
same line (Fig. 1b). generated from the anaerobic digestion of sewage sludge
produced at Henriksdal sewage treatment plant (Balken-
Taking into account the results from Fig. 1, the fol-
hoff and Jamieson 2008). The biogas from Gryta waste
lowing aspects can be noted (Cozma et al. 2013a):
treatment plant is upgraded to fuel quality at Gryta biogas
– the results from UNIQUAC and NRTL models did not upgrading plant which has a capacity of 150–550 Nm3/h
show a good agreement with the experimental CO2 raw biogas (Växtkraft project 2004). DVGW R&D-pro-
solubility for pressures above 10 bar; gram ‘‘Biogas’’ takes part from DVGW Research Projects
– NRTL-RK, UNIQ-RK, and ELECNRTL showed a (DVGW—Deutsche Vereinigung des Gas- und Wasserf-
good agreement with experimental data in all condi- aches e. V. - Technical and Scientific Association for Gas
tions presented. and Water), which provides important data for biogas
production, biogas purification, and injection to the gas
As a main finding, the experimental data are accurately
grid from Germany (Graf and Klaas 2009). Graf and Klaas
reproduced by all the models applied under the conditions
(2009) from DVGW Research Station at Engler-Bunte-
of absorption interest (pressure up to 10 bar). NRTL and
Institut, Universität Karlsruhe analyzed the biogas com-
UNIQUAC methods are proper for simulations pressures
position from three plants with PSA, water scrubber and
up to 10 bar without including the critical region, as stated
one plant with a Genosorb scrubber. From this study, only
by Carlson (1996). Therefore, NRTL model was chosen for
the data corresponding to HPWS technology are presented
further analysis (Cozma et al. 2013a).
in Table 1. The water scrubbing process implemented by
Darmstadt–Wixhausen was delivered by the company
Malmberg in Sweden. The calculations take into account
Simulation of physical absorption process applied the gas quality and requirements for biogas injection
for biogas upgrading according to DVGW Gas quality G 260/G262.

Literature survey: available process data Process description and process flow diagram

Available literature data regarding HPWS technology with The operational conditions of the case study were estab-
the possibility of regeneration and recirculation of water is lished based on data taken from the literature. The default
very scarce (Table 1). In general, plant capacity, biogas parameters are presented in Table 2 (Cozma et al. 2013b).
and product gas composition, working pressure, and in Figure 2 shows the flow diagram for pressurized water
some cases make-up water values are the basic data spec- scrubbing which involves the regeneration and recircula-
ified on a biogas upgrading plant. Moreover, an important tion of water.
part of operating parameters affecting the efficiency of the According to simulation studies presented in the first
process (the quality of the upgraded biogas) is missing. part of paper, UNIQUAC and NRTL are in excellent
From these reasons, difficulties were encountered in agreement at pressures up to 10 bar. Therefore, the NRTL
simulation of HPWS process using the experimental data property method was used to describe physical absorption.
from the related literature. Basically, missing parameters Absorber and stripper were modeled in Aspen using Rad-
were estimated developing different sensitivity analysis frac modules without condenser and reboiler. The equi-
and taking into account the most important study of Götz librium-stage approach in the gas–liquid system was used
et al. (2011) from the literature. for modeling the absorber and stripper units (Cozma et al.
Also, the DMT TS-PHPWSÒ was taken into account, 2013b).
which is a guaranteed technology (with references since The simulated scrubbing process has been described
1986) for removing of CO2, H2O, H2S, and various other previously (Cozma et al. 2013b; Dirkse 2010; Petersson
pollutants from biogas with minimal waste streams. At and Wellinger 2009; Persson et al. 2006; Persson 2003)
different plant capacity from 250 to 2,000 Nm3/h, the (Fig. 2): after being pressurized to 10 bar (in the com-
performances of this technology include (Dirkse 2010): pressors COMP1, COMP2), the incoming biogas contain-
more than 97 % methane content in product gas, less than ing 60 % CH4, 38.9 % CO2, 300 ppm H2S, 0.5 % N2, and
2 % CO2 content, less than 2 % methane losses, high 0.5 % O2 enters the bottom of the scrubber (ABSORBER),
efficiency on removal H2S in one step (\2 ppm in outlet while water is fed from the top of the column (LIQ-IN).
gas), low power consumption (0.4–0.5 kWh/m3 produced The technological process flow is alike to that descri-
gas), and high energy. Henriksdal biogas upgrading plant bed previously (Cozma et al. 2013a, b): the CO2-enriched
from Stockholm, Sweden was initially built with a capacity water leaving the scrubber (RICH-SOL) is transferred to

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Modeling and simulation of high pressure water scrubbing technology

Table 2 Specifications for Parameters Units Most likely parameters values Our default parameters
base-case simulation (based on the literature data) values (NRTL model)
(equilibrium calculations)
(Cozma et al. 2013b) CH4/CO2 vol% 55–65/35–45 60/38.97
H2S ppm 100–1,500 300
N2/O2 vol% 0.5/0.5
Pabsorber bar 8–10 10
Tabsorber °C 20 20
Tstripper °C 20 20
Plant capacity (GFR) Nm3/h 150–2,000 500
Make-up water (WFR) kg/h 500–5,000 2,000
3
Air flow rate (AFR) Nm /h 1,000
Water pump-around (WPA) m3/h 82.5
Pflash bar 2–4 3
Pstripper bar 1 1
Number of theoretical stages 7
L/GFR vol-based 0.2 0.169
VWFR/VGFR vol-based 0.0015–0.0045 0.004
VWFR/VWPA vol-based 0.0242
VWPA/VGFR vol-based 0.197 0.165
VAFR/VGFR vol-based 2 2
Comparison of the results from the literature with our results obtained through simulation
CH4,Recirc. to compressor (%) 94.065
CO2,Recirc. to compressor (%) 38.6
CO2 RE (%) [97 97.6
Methane loss (%) \2 0.313
Treated flow rate Nm3/h 309.36
Product gas (PG)
CO2 mole fraction \0.02 0.0093
The main available data are CH4 C0.97 0.967
taken from the existing
H2S \1 ppm 0.006 ppm
commercial plant, such as DMT
TS-PHPWSÒ Technology N2 0.01–0.033 0.0113
(Dirkse 2010); Henriksdal O2 0.0009–0.0078 0.00976
biogas upgrading plant from H2O 0.00228
Stockholm, Sweden
(Balkenhoff and Jamieson Off gas (SG)
2008); Gryta waste treatment CO2 mole fraction 0.157
plant (Växtkraft project 2004); CH4 0.0007–0.004 0.000767
DVGW R&D-program
H2S 20–90 ppm 123 ppm
‘‘Biogas’’ (Graf and Klaas
2009). Götz et al. (2011) study N2 0.6–0.7 0.647
is one of the most important O2 0.16–0.19 0.171
studies which provide important H2O 0.022
data on HPWS technology

the flash column (FLASH), where the pressure is reduced a temperature of 20 °C (GAS-EXIT). Subsequently, the
from 10 to 3 bar in order to minimize methane loss. The water is recirculated (LIQ-STR) back to the top of the
gas containing CO2, CH4, H2S, N2, O2, and water released scrubber. Based on the initial process conditions, it was
from the flash column (GAS-REC) is mixed with the raw calculated that the gas leaving the scrubber contains:
biogas (MIXER) and recirculated to the inlet of the 96.72 % methane, 0.937 % CO2, 0.006 ppm H2S, 1.1 %
compressor (COMP2). After leaving the flash column, the N2, and 0.976 % O2. Methane loss is very low, that is
rich solution (SOL-FL) is sent to the desorption column 0.313 %. It is assumed that the water stream is recycled
(STRIPPER), where it meets a counter flow of air (AIR- continuously (in a closed loop), so that only 2 m3/h,
STR), into which carbon dioxide and hydrogen sulfide are which means 2.4 % of circulating water flow rate (i.e.,
released from water at regular atmospheric pressure and at 84.5 m3/h) is evaporated, or otherwise lost.

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P. Cozma et al.

Fig. 2 Aspen Plus model for a biogas upgrading plant based on absorption with regeneration and recirculation of water (Cozma et al. 2013b)

Validation of the equilibrium model applied in this only 1.5 % originating from the flow rate of the circulating
study with the literature data water was either evaporated, replaced during the process,
or otherwise lost. Our data showed that eleven theoretical
Götz et al. (2011) work is one of the most important studies stages would be suitable in achieving equilibrium, and
which provide important data on HPWS technology. There nearly the same gas outlet composition as in the study of
is no other study in the literature to provide such detailed Götz et al. (2011) will result. Since no significant errors
data on the performance of HPWS process. Therefore, this were found among the results of Götz et al. (2011) and ours
work was selected to validate the equilibrium-stage model (Table 3), we concluded that this simulation is validated
applied in the present study (Table 3) (Cozma et al. and the associated data from Table 2 can be used for fur-
2013b). ther analysis (e.g., to simulate the HPWS technology)
The authors studied the influence of pressure, regenera- (Cozma et al. 2013b).
tion temperature, water pump-around consumption, air flow
rate, and other parameters on the HPWS technology applied Equilibrium approach
for biogas upgrading. The results are based on equilibrium
calculations using Aspen Plus software and validated by The first step of the present study consisted in theoretical
real measurements. The authors used the ELECNRTL calculations of the number of stages and minimum and
thermodynamic method to describe the interactions of the optimum water flow rate necessary for the absorption
two-phase system. BINARY databank from available process in the conditions presented in Table 2 (default
Aspen data base was used to describe Henry’s coefficients. parameters). The theoretical contact stages were deter-
The authors’ calculations take into account the gas quality mined graphically using the material balance for absorption
and requirements for biogas injection according to DVGW and gas–liquid equilibrium diagram. The minimum liquid
Gas quality G 260 of ‘‘German Association of Gas and flow rate was also calculated taking into account the
Water Industry Directive.’’ equilibrium data of the system and the material balance.
In our study, validation of the equilibrium model was Generally, in practice the optimum liquid flow rate is 1.5
achieved using the same working conditions reported by times the minimum liquid flow rate (US EPA 2010).
Götz et al. (2011). Finally, the upgraded biogas and off gas According to calculations, six theoretical stages and an
composition are compared in Table 3 (Cozma et al. 2013b). optimum total water flow rate of 84.5 m3/h were necessary
Since the number of theoretical stages, as well as the to achieve an imposed CO2 RE (%) of 97 %, which is
amount of fresh water inlet or the amount of water which is equivalent with a final concentration of approximately
continuously replaced due to the evaporation during the 0.011 mol fraction CO2 in the upgraded biogas. In calcu-
process was not specified in Götz et al. (2011) work, we lations, pure water was considered, therefore the initial
developed a preliminary study to determine the minimum CO2 concentration in liquid phase was zero. Simulations
number of stages and absorbent flow rate required to showed that a number of six stages are quite adequate to
achieve equilibrium. It was considered that only the water achieve almost the desired CO2 RE (%) (the final CO2
lost due to evaporation was replaced, so that almost no concentration was 0.0165 mol fraction and removal effi-
fresh water was used. Therefore, we considered a total ciency of *96). In these conditions, the methane content in
water flow rate of 47.8 m3/h, as mentioned in Table 3, product gas was only 96 vol%. Because the water is
assuming that the water was completely recycled, since regenerated and recirculated it may also contain a small

123
Modeling and simulation of high pressure water scrubbing technology

Table 3 Operating parameters Parameters Units Götz et al. (2011) Our simulation
(literature versus our simulation
data) (Cozma et al. 2013b) CH4/CO2 vol% 53.7/45.2 53.62/45.2
H2S/H2 ppm 101.8/508 100
N2/O2/H2/H2O vol% 0.93/0.19 0.93/0.19/0.05/–
Pabsorber bar 8/(6–17) 8
Tabsorber °C 20 20
Tstripper °C 20 20
Plant capacity (GFR) Nm3/h 242.3
kmol/h 10.854
WFR (% evaporated water per hour of WPA) % 1–10 % 1.5 %
kg/h 720
AFR Nm3/h 515.6
kmol/h 23
WPA m3/h 47.8
kg/h 47,720
Pflash bar 3 3
Pstripper bar 1 1
Number of theoretical stages 11
L/GFR vol-based 0.2
VWFR/VGFR vol-based 0.003
VWFR/VWPA vol-based 0.015
VWPA/VGFR vol-based 0.197/(0.11–0.30) 0.197
VAFR/VGFR vol-based 2.128/(0.13–0.32) 2.128
Comparison of the results from Götz et al. (2011) with our results obtained through simulation
CO2 RE (%) 98.96 99.12
Methane loss (%) 0.36 0.326
Treated flow rate Nm3/h 133.9 134.35
Product gas (PG)
CO2 mol fraction 0.0047 0.00397
CH4 0.968 0.965
H2S 1 ppm 0.000094 ppm
N2 0.021 0.0209
O2 0.0056 0.00563
H2 0.000902
H2O 0.0032 0.00319
Off gas (SG)
CO2 mol fraction 0.175 0.171
CH4 0.0007 0.000677
H2S 39.5 ppm 38 ppm
N2 0.652 0.635
The figures in bold highlights
the similar performance of the O2 0.173 0.168
system, as obtained by G} otz H2 0.193 ppm
et al. 2011 and resulted from our H2O 0.0231 0.0234
simulation.

amount of CO2. Therefore, the initial concentration of CO2 of circulating water (84.5 m3/h) was evaporated, otherwise
in liquid will be somewhat greater than zero and the lost and replaced during the process.
number of theoretical stages could increase. Moreover, we The equilibrium model was used to evaluate the effects of
want to obtain higher methane concentration in the changing the most important operating parameters on pro-
upgraded biogas. Therefore, it was decided to increase the cess efficiency. The results are summarized in terms of
number of stages at 7. It was assumed that water was system efficiency (assessment of CH4 enrichment, methane
recycled continuously (closed system) and 2.4 % per hour loss, CO2 removal).

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P. Cozma et al.

Fig. 3 Influence of number of stages on a YCH4,PG (vol%) and M%, b CO2 RE (%), c YCH4,SG (vol%), d CH4,Recirc. (%) and CO2,Recirc.
(%), e YH2S,PG (vol%) (WFR = 2 m3/h; WPA = 82.5 m3/h; GFR = 500 Nm3/h; Pabsorber = 10 bar; T = 20 °C; Pflash = 3 bar)

Results of the simulation CO2 recirculation (%), H2S content in product gas (YH2S,PG
(vol%)) at constant gas and water flow rate is presented in
Sensitivity analysis (equilibrium calculations): factors Fig. 3. YCH4,PG (vol%) and CO2 RE (%) increased by
affecting process efficiency increasing the number of stages. Methane loss (M %) and
YCH4,SG (vol%) decreased from 0.47 to 0.288 and from
Theoretical number of stages 0.116 to 0.068 vol%, respectively, by increasing the number
of stages from 4 to 10. Due to relatively lower content of H2S
The influence of number of stages on methane content in in raw biogas (300 ppm) almost a complete of its removal
product gas (YCH4,PG (vol%)) and off gas (YCH4,SG was achieved. The results showed that YH2S,PG (vol%)
(vol%)), CO2 removal efficiency (CO2 RE (%)), CH4 and decreased from 0.783 to 3.39 9 10-11 ppm by increasing

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Modeling and simulation of high pressure water scrubbing technology

Fig. 4 Influence of L/GFR ratio on a YCH4,PG (vol%) and M%, b CO2 RE (%), c CH4,Recirc. (%) and CO2,Recirc. (%) (seven equilibrium
stages; constant WFR of 2 m3/h; constant GFR of 500 Nm3/h; Pabsorber = 10 bar; T = 20 °C; Pflash = 3 bar)

the number of stages from 4 to 14. Further, the recirculation costs as well, since a greater number of stages will require
of CH4 and CO2 increased from 92 to 94.47 and from 31.2 to a taller column. Therefore, an optimum number of stages
40.4 %, respectively, along with increasing the number of should be specified based on required amount of water
stages. absorption and economic aspects. Taking into account that
Even if involves a simple dissolution of gases in water the column absorption from the present study was designed
under pressure, the absorption is a complex process. for *97 % CO2 removal efficiency, seven absorption
Increasing the number of equilibrium stages favors the stages were chosen for further analyses.
absorption rate in water. More CO2 is dissolved and as a
consequence CO2 RE (%) and YCH4,PG (vol%) increased. L/GFR ratio
Methane loss decreases along with YCH4,PG (vol%)
increases. Moreover, it was observed that methane losses First, we should mention that L/GFR ratio must be greater
will be lower if more amount of methane is recirculated. than a minimum established value. Thus, the minimum
On the other hand, increasing the number of equilibrium total water flow rate of 56.31 m3/h (obtained according to
stages favors also the desorption of CO2. At a constant theoretical calculations) was multiplied by an k fac-
water flow rate and highest number of stages, the concen- tor = 1.05; 1.1; 1.2; 1.3; 1.4; 1.5 in order to obtain the
tration of CO2 in liquid phase is minimum since more CO2 maximum total water flow rate necessary to achieve
will desorb. Since the concentration of methane in product approximately 97 % RE of CO2. The amount of water
gas is maximum its concentration in off gas is minimum which is evaporated was kept constant (WFR = 2 m3/h)
(e.g., YCH4,SG (vol%) decreased from 0.116 to and only the amount of recirculated water (WPA) was
0.068 vol% by increasing the number of stages from 4 to varied. Increasing L/GFR ratio from 0.112 to 0.169 m3
10). H2O/Nm3 raw biogas improved gas purity but in the same
As discussed previously, increasing the number of time increased methane loss (Fig. 4).
equilibrium stages increases the absorption rate in water, An increase of L/GFR ratio above the minimum value
but this will increase the manufacture and maintenance (Lmin/GFR ratio) at constant number of stages led to an

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P. Cozma et al.

Fig. 5 Influence of fresh water flow rate to gas flow rate ratio (VFWFR/VGFR ratio) on a YCH4,PG (vol%) and M%, b CO2 RE (%) (seven
equilibrium stages; constant WPA of 84.5 m3/h; constant GFR of 500 Nm3/h; Pabsorber = 10 bar; T = 20 °C; Pflash = 3 bar)

Fig. 6 Influence of number of stages at different fresh water to gas flow rate ratio (VFWFR/VGFR ratio) values on a YCH4 and PG (vol%), b CO2
RE (%), c M%, d H2S,PG (ppm), and e CH4,Recirc. (%)

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Modeling and simulation of high pressure water scrubbing technology

Table 4 Influence of biogas composition on process efficiency thus enhancing the CH4 content in PG from 96.796 to
Biogas composition YCH4PG M% CO2 RE CH4,REC
97.325 vol%, along with variation of VFWFR/VGFR ratio
CH4/CO2 (vol%) (vol%) (%) (vol%) from 0.002 to 0.016 m3/Nm3 raw biogas (Fig. 5). The H2S
concentration in PG decreased from 0.0058 to
55/43.97 92.45 0.158 88.37 96.29
0.00281 ppm, while N2 and O2 are not reduced in any
60/38.97 96.6 0.313 97.43 93.88 conditions (data not shown). We can observe also an
65/33.97 97.2 0.578 98.2 90.11 increase of M% with increasing of VFWFR/VGFR ratio. This
behavior is similar as in the case presented above (Fig. 4).
Therefore, the explanation is the same: the introduction of
Table 5 The influence of N2 and O2 amount on methane content in
product gas
larger quantities of water for absorption involves the dis-
posal of larger quantities of water from the system which
Components Biogas composition (vol%) PG composition contains more methane (LIQ-OUT stream). This explains
CH4 0.3987 0.0129 vol% the increases of methane loss along with VFWFR/VGFR ratio
CO2 0.6 0.978 vol% increase.
H2S 0.0003 0.00774 ppm Figure 6 shows the influence of number of stages on
N2 0.0005 0.00407 vol% product gas composition at different fresh water to gas flow
O2 0.0005 0.00252 vol% ratio values. Increasing both the amount of fresh water and
the number of stages increased the absorption capacity of
the system. It can be observed that YCH4,PG (vol%), CO2
RE (%), and YH2S,PG (vol%) increased with increasing
increase of CO2 removal efficiency. This means that lower both the number of stages and VFWFR/VGFR ratio. We
concentrations of CO2 in gas phase are released from should mention that above ten stages the product gas
absorber and the absorption rate in water increases. Since composition became constant. As expected, an increase of
YCH4,PG (vol%), CO2 RE (%), CH4,Recirc. (%), and water amount involves also an increase of M%. The
CO2,Recirc. (%) increase with increasing L/GFR ratio, we behavior is closely as in the cases presented in Figs. 4 and
rather expect in a decrease of methane loss. But we can 5. However, it should be noted that increasing the amount
observe a contradictory behavior, since M% increases of total water greater costs can be involved since larger
along with L/GFR ratio increase. This is because an amount of recirculated water implies higher energy
increase of L/GFR ratio also favors a higher retention of consumption.
CH4 in water. Even CH4 has a lower solubility in water
compared with CO2, some amount of CH4 is also dis- Biogas composition
solved, even more larger amounts of water are added. Thus,
methane is lost with liquid discharge from desorber (LIQ- The influence of biogas composition on methane content in
OUT stream). In other words, the introduction of greater product gas, CO2 RE (%), methane loss, CH4,Recirc. (%)
quantities of water for absorption involves the disposal of at constant water and gas flow rates, and seven equilibrium
larger quantities of water from the system which will stages is presented in Table 4. It can be observed that
contain more methane. This explains the increases of YCH4,PG (vol%), CO2 RE (%), and M% increased by
methane loss along with L/GFR ratio increase. varying biogas composition. Is obvious that having a lower
Most of the commercial upgrading plants are not able to initial concentration of CO2 in gas phase its removal effi-
recycle the water completely and so that almost 1–10 % of ciency will increase. By reducing the initial amount of N2
water is replaced every hour (Lantela et al. 2012; Persson and O2 from 0.5 to 0.05 vol%, the methane content in
2003). Even it was assumed that the water was recycled product gas increased as can be seen in Table 5.
continuously (closed system) and only the amount of
evaporated water is replaced, further analysis is focused on Pressure in absorber
adding different amounts of fresh water in the system,
besides the water evaporated, in order to increase the Further analysis is focused on testing the effect of different
absorption capacity of the column. pressure levels in the absorption column. Henry’s constant
The amount of recirculated water (WPA = 84.5 m3/h) is an indirect measurement of the solubilities of gases in
and number of stages were kept constant, while the amount liquids. In turn the solubility is influenced by temperature,
of fresh water was varied between 1 and 10 % from total pressure, and system type. The solubility decreases with
amount of 84.5 m3/h water. Increasing the amount of fresh increasing the temperature and increases with increasing
water increased the absorption capacity of the system. the pressure. It can be anticipated that CO2 RE (%) will
Actually CO2 RE (%) increased from 97.82 % to 99.217, increase by increasing the feed biogas pressure in the

123
P. Cozma et al.

Fig. 7 Effect of working pressure on a YCH4,PG (vol%), b M%, c CO2 RE (%), d CH4,Recirc. (%) at different L/GFR ratio (7 equilibrium
stages; constant WFR of 2 m3/h; constant GFR of 500 Nm3/h; T = 20 °C; Pflash = 3 bar)

Fig. 8 Influence of temperature in absorber on a YCH4,PG (vol%) and M%, b CO2 RE (%), c CH4,Recirc. (%) and CO2,Recirc. (%)

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Modeling and simulation of high pressure water scrubbing technology

Fig. 9 Influence of pressure in flash on a YCH4,PG (vol%) and M%, b CO2 RE (%), c CH4,Recirc. (%) and CO2,Recirc. (%)

absorption column because of the enhanced CO2 solubility results indicated that a higher pressure could compensate
at higher pressures (Marzouk et al. 2010). for lower absorbent flow rate since at 17 bar and lower
The effect of system pressure on CH4 content in product L/GFR ratio the amount of methane from PG is the same as
gas, methane loss, CO2 RE (%), and the recirculation of CH4 at 20 bar and higher L/GFR ratio. It can be noticed that a
at fixed gas and water flow rates (L/GFR = 0.169 m3 H2O/ significant reduction of methane loss is obtained at lower
Nm3 raw biogas) was investigated and the results are shown L/GFR ratio and high pressure (at 20 bar the methane loss
in Fig. 7. Carbon dioxide removal efficiency increased with was 0.09 %).
increasing pressure, as expecting according to Henry’s law. However, increasing the system pressure results in
More CO2 is dissolved and as a consequence the methane higher power consumption by the raw gas compressors
content in product gas (YCH4,PG (vol%)) increased. (Lampert and Ziebik 2007), since gas compression is fol-
Moreover, as the amount of methane in product gas lowed by a sharp increase in temperature and an additional
increased the methane loss decreased (M% is reduced from gas cooling step is required, which adds to the overall
0.817 to 0.274 % at pressures between 6 and 20 bar). At energy consumption.
pressures above 13 bar, the product gas composition became
constant. At 6-bar working pressure, higher amount of CO2
was found in product gas (81.864 kg/h or 0.12 mol fraction) Initial temperature in absorber
as at 17 bar (0.082 kg/h or 137 ppm CO2). The highest CH4
content of 97.7 vol% was obtained at 20 bar, while the CO2 Solubility of gases in water and diffusion coefficients
removal efficiency was almost complete (99.96 %). varies with temperature (Moradi 2010; Sjöstrand and Yazdi
The effect of feed gas pressure in the absorption column 2009). Therefore, the solubility of gases in water decreases
on product gas content at different water flow rates and by increasing the temperature, according to Henry’s law,
fixed gas flow rate (different L/GFR ratios) was also meanwhile the liquid-phase diffusion coefficients decrease
studied. The results are combined with that from Fig. 7. with decreasing the temperature (Moradi 2010), lowering
Actually, only the amount of recirculated water was the CO2 removal efficiency. It should be noted that only the
changed, and the WFR was kept constant at 2 m3/h. The inlet temperature of gas and water in absorption column

123
P. Cozma et al.

Fig. 10 Overall process mass balance at 3 bar pressure in flash (Cozma et al. 2013b)

was changed. The temperature in flash and stripper was content in PG decreased from 0.153 to 0.002 ppm. N2 and
maintained at 20 °C. O2 content increased from 0.96 to 1.19 and from 0.829 to
Figure 8 shows the effect of temperature on CO2 RE 0.998 %, respectively, by changing the pressure in flash
(%), YCH4,PG (vol%), M%, CH4,Recirc. (%), and CO2,- from 2 to 10 bar. In the exhaust gas, carbon dioxide content
Recirc. (%). As expected, CO2 RE (%) decreased by ranged from 11.85 % to 15.64 vol%, methane content from
increasing the temperature. Lower amounts of CO2 are 0.018 % to 1.63 vol%, H2S content from 0.0128 % to
dissolved in water and as a consequence the methane 0.012 vol%, nitrogen content from 67.8 to 63.5 vol%, and
content in product gas decreased. Moreover, as the amount oxygen content from 18 to 16.87 vol%.
of methane in product gas decreased the methane loss The recirculation of gas is strongly dependent by the
increased. It is obvious that this behavior is vice versa pressure in flash, thus the recirculation of CH4 and CO2
versus the effect of pressure levels in the absorber column. decreased by increasing the pressure in flash. At 10-bar
pressure in flash, no CH4 or CO2 recirculation is involved,
Pressure in flash but the methane loss is very high (6.72 %).
First, we should mention that the dependencies presented
The loss of methane is important both from economic and above are obtained taking into account the calculations on
environment point of view (Nozic 2006). Therefore, it is the entire system. At equilibrium conditions, a concentration
essential to find the optimum combination of operating of CO2 in liquid phase exists which depends on pressure. At
parameters that will give the best results with regard to pressure of 10 bar, the concentration of CO2 in liquid phase
methane loss, YCH4,PG (vol%) and CO2 RE (%). The ðXCO2 ;p¼10 Þ is higher compared to that at 3 bar ðXCO2 ;p¼3 Þ: At
influence of the pressure in flash on methane content in the exit of flash, there are two phases: a liquid phase that
product gas, methane loss, CO2 RE (%), and the recirculation passes to desorber (SOL-FL) with the concentration
of gas at fixed gas and water flow rates (L/ ðXCO2 ;p¼3 Þ which is much lower than at the inlet ðXCO2 ;p¼10 Þ
GFR = 0.169 m3 H2O/Nm3 raw biogas) are shown in Fig. 9. (RICH-SOL) and a gas phase which is recycled to absorber
The pressure in flash was varied from 2 to 10 bar. It can (GAS-REC). A large decrease of pressure (in our case from
be observed that YCH4,PG (vol%), M%, and CO2 RE (%) 10 to 3 bar) resulted in large amount of recirculated gases
increased by increasing the pressure in flash. The H2S and to a decrease of efficiency. The pressure in flash was

123
Modeling and simulation of high pressure water scrubbing technology

chosen to be 3 bar to avoid the presence of large amounts of – the H2S content in the product gas was much less than
methane in liquid phase. In other words, the liquid phase 1 ppm almost in all the conditions studied.
from flash flows to stripper where desorption takes place
For biogas upgrading process, it is important to find the
(methane is released from liquid phase and passes to gas
optimum combination of operating parameters that will
phase). Therefore, large quantities of methane can pass into
give the best results with regard to methane loss, YCH4,PG
gas outlet of desorber if initially high amounts of methane
(vol%) and CO2 RE (%) (Cozma et al. 2012).
exist in liquid phase.
For a better understanding of the system behavior,
overall process mass balance at 3-bar pressure in flash is
Conclusions
shown in Fig. 10 (for more details on energy consumption
please see the paper of Cozma et al. 2013b).
Of all available biogas upgrading technologies with a high
After a brief analysis, the main conclusions of this
potential to produce large amounts of upgraded biogas,
section can be drawn:
HPWS has been chosen for analysis in the present study.
– the quality of the product gas (which contains 96.7 % This is a well-known technology and is currently the most
methane, 1 % CO2, 0.006 ppm H2S, 1.1 % N2, and effective upgrading process. In spite of this, the related
0.974 % O2) from this case study is suitable for vehicle literature provides very little information concerning the
fuels since matches the requirements from the Swedish influence of operating conditions and design parameters on
Standard on biomethane SS 155438 ‘‘Motor fuels – upgraded biogas composition.
Biogas as fuel for high-speed Otto engines’’: CH4 We concluded that the equilibrium results showed that
97 ± 2 %; CO2 \4 %; CO2 ? O2 ? N2 max. 5 %; biogas can be upgraded to 96.6 % methane content using a
– increasing the number of equilibrium stages increases counter-current HPWS process at 10-bar pressure and
the absorption rate in water but this will increase as 20 °C temperature.
well the manufacture and maintenance costs, since a In this work, we have also discussed the procedures for
greater number of stages involves a higher column; improving a biogas upgrading plant as well as the main
however, above ten stages the product gas composition factors which influence the process efficiency. In this
became constant; it should be noted that greater costs manner, a basis for further research was provided. An
could be involved since larger amount of recirculated optimum combination of operating parameters must give
water implies higher energy consumption; the best results with regard to methane content in product
– increasing L/GFR ratio (m3 H2O/Nm3 raw biogas) gas, methane loss, and CO2 removal, taking into account
improved gas purity but in the same time increased the energy consumption and the amount of water necessary
methane loss; for absorption process. Further research in this area is
– the absorption capacity of the system increased along focused on the calculation of the rate of mass and heat
with increasing the amount of fresh water; transfer between the gas and liquid phases, liquid and vapor
– increasing the pressure in the absorber enhanced the film diffusion or equipment hydrodynamics using the rate-
methane content in product gas and CO2 RE (%) but based model available in Aspen Plus simulation tool.
also decreased the methane loss; however, with
increasing the pressure higher power consumption will Acknowledgments This paper was carried out with the support of
EURODOC ‘‘Doctoral Scholarships for research performance at
be registered by the raw gas compressors; European level’’ Project ID_59410, financed by the European Social
– higher pressure could compensate for lower absorbent Found and Romanian Government. The support of the Institute of
flow rate; Chemical Engineering - Vienna University of Technology, Austria in
– it is a difficult task to find the optimum pressure in flash using Aspen Plus software tool is highly acknowledged. This work
was partially supported by the Grant of the Romanian National
since many factors must be considered; the methane Authority for Scientific Research, CNCS – UEFISCDI, Project
loss and energy consumption could be some important Number PN-II-ID-PCE-2011-3-0559, Contract 265/2011.
factors to take into account;
– oxygen and nitrogen cannot be removed from raw
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