Opportunities for integration of carbon capture process with coal-fired power plants
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The Rotterdam Capture and Storage Demonstration Project (ROAD) recently completed a report for the Global CCS Institute identifying the opportunities for integrating carbon capture process with the main power generation process and for optimising the efficiency of the power plant and carbon capture unit. At this webinar, Hette Hylkema, Special Area Manager MPP3 Interface and Andy Read, Director Capture for ROAD Maasvlakte CCS Project C.V., presented the findings of such integration interfaces based on the experience of ROAD, explain major design choices/solutions and discuss the lessons learnt for future CCS projects.
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Opportunities for integration of carbon capture process with coal-fired power plants
- 1. Opportunities for integration of carbon capture process with coal-fired power plants Webinar – 4 February 2014, 1900 AEDT
- 2. Hette Hylkema Hette Hylkema is a Project Manager with an excellent understanding of power plant technology and economics. In 2009 he had the lead in the conceptual design of the integration of the 250MW demonstration CCS plant and the Maasvlakte Power Plant Unit 3. He has previously worked on several new build projects, most notably the development of the 225 MW RoCa3 CHP plant, that was built for the delivery of heat and CO2 to a greenhouse area. Hette has over 30 years of experience in the power industry, including design and project development. On the ROAD Project Hette is responsible for the engineering of the interfaces with E.ON’s MPP3 Power Plant (the host for the CCS demonstration).
- 3. Dr Andy Read Andy Read is a Project Manager with an excellent understanding of power plant technology and the electricity markets with the associated commercial constraints. For the last five years, he has focused on CCS project development leading projects at Killingholme and Kingsnorth in the UK, and now as Capture Director for the E.ON / GDF SUEZ joint venture at Maasvlakte, Netherlands (ROAD Project). He has previously worked on several new build projects, most notably the early development of the 1275MW Grain CHP plant, and acted as interface between commercial functions (such as Strategy and Trading) and the power plant asset managers. Andy has 20 years of experience in the power industry, including design and operation of supercritical coal power plant, combustion technology and a stint on an operating coal-fired power station. In Andy’s current role, he is one of four directors responsible for the ROAD Project – a 250MW CCS demonstration in Rotterdam, due to be in commercial operation by 2015. He has responsibility for the engineering, design and construction of the Capture Plant including the interfaces with E.ON’s MPP3 Power Plant (the host for the CCS demonstration)
- 4. QUESTIONS We will collect questions during the presentation. Your MC will pose these questions to the presenters after the presentation. Please submit your questions directly into the GoToWebinar control panel. The webinar will start shortly.
- 5. Integration of Capture Plant and Power Plant Hette Hylkema, Special Area Manager MPP3 Interface Webinar Global CCS Institute, 4 February 2014
- 6. Agenda • Project overview • Main interfaces • • • • Flue Gas tie-ins Steam/condensate supply Electric supply Cooling water • Other interfaces • Operation and emissions • Lessons learned 6 Page 6
- 7. State of Play ROAD • Engineering • Detail engineering of capture plant ready • Pipeline route engineered, ‘flow assurance’ study completed • ‘Tie-ins’ (i.a. flue gas, steam) with power plant installed • Permits • Permitting procedures finalized (beginning 2012) • Capture and storage permits are definitive • Publication definitive transport permits soon • Contracts • Capture supplier selected and EPC contract ready to be signed • Negotiations with storage operator (TAQA) on storage progressing well and in final stage • Finance • Very low CO2 prices have caused a financing gap • ROAD, parent companies and other stakeholders are currently working on solution for financial gap ROAD is ready to start construction as soon as financial gap has been solved Page 7
- 9. Maasvlakte Power Plant 3 of E.ON • • • • • • Output Combustion process Fuel Efficiency Operational Capture ready : 1 070 MWe, single train unit : Pulverised coal boiler : Hard coal blends from different countries : 46% : 2013 (first synchronisation) Page 9
- 10. Carbon Capture Plant • Capture technology • Technology provider • Capture capacity • Capture rate • Capture volume • Operational : Post combustion : Fluor : 250 MWe equivalent (23.4% of flue gas from MPP3 is treated) : 90% : ̴ 1.1 Mt/a : 2017 • Transport • Storage : 25 km; 16 inch; gas phase : depleted gas reservoir P18-A Page 10
- 12. Flue Gas to Capture Plant Page 12
- 13. 3D Model Capture Plant Page 13
- 14. CCS-MPP3: Process Scheme Carbon Capture Plant Controls Drinking water Fire water Storm water Sewage Electric Power 14 Page 14
- 15. Agenda • Project overview • Main interfaces • • • • Flue Gas tie-ins Steam/condensate supply Electric supply Cooling water • Other interfaces • Operation and emissions • Lessons learned 15 Page 15
- 16. Planning Two time critical interfaces: • Flue Gas tie-ins • Steam/condensate tie-ins • To avoid long outage costs MPP3 (8 -12 weeks) execution of the critical interfaces is planned before commissioning MPP3. All other after commissioning MPP3. Page 16
- 17. Flue Gas Extraction at Stack of MPP3 Page 17
- 18. Total Power Loss for Steam and Power Supply MWe Steam and Power Options 47% 1 090 46% 1 070 45% 1 050 44% 1 030 1 010 43% 990 42% 970 41% 950 40% Total Power Electrical Efficiency Page 18
- 19. Reboiler Steam: Option 6 DN 400 HP MP LP A5 LP DN 1400 DN 1200 SPAT MPP1/2 condenser Fd Wtr Tk DN 400 DN 400 PIC DN 600 DN 400 LP A5 PIC MPP3 with CCS A5+cold reheat with steam jet pump DN 400 DN 500 HP Prhtr 2 DN 300 DN 300 DN 600 DN 400 DN 600 boiler Air Prhtr LP Prhtr 5 DN 400 PIC 1200 / 900 300 / 250 TIC FIC CO2 compressor stripper DCC absorber TIC FIC LIC PI PI DN 150 FIC 250 / 300 250 / 300 Alternative 2 Alternative 1 Fd Wtr Tk Page 19
- 20. Reboiler Steam: Tie-ins DN 400 HP MP LP A5 LP DN 1400 DN 1200 SPAT MPP1/2 condenser Fd Wtr Tk DN 400 DN 400 PIC DN 600 DN 400 LP A5 PIC MPP3 with CCS A5+cold reheat with steam jet pump DN 400 DN 500 HP Prhtr 2 DN 300 DN 300 DN 600 DN 400 DN 600 boiler Air Prhtr LP Prhtr 5 DN 400 PIC 1200 / 900 300 / 250 TIC FIC CO2 compressor stripper DCC absorber TIC FIC LIC PI PI DN 150 FIC 250 / 300 250 / 300 Alternative 2 Alternative 1 Fd Wtr Tk Page 20
- 21. Reboiler Steam: Option 6 (Steam Jet Booster) Page 21
- 23. Cooling Water: Selected Option • Overall cooling demand capture plant: ~200 MW • Cooling demand CO2 compressor: ~20 MW • Three options evaluated to connect to MPP3 sea cooling water system to avoid high CAPEX in dedicated cooling water system Main Cooling Water Pumps 1 2 MPP 3 5 Discharge Pond 3 CO2 Capture Section 23 Condensate from MPP3 A CO2 Compressor and Desorber Head 4 B Condensate to MPP3 Page 23
- 24. Cooling Water: Options not selected Main Cooling Water Pumps 1 2 3 Main Cooling Water Pumps 1 4 MPP 3 CO2 Capture and Compression Section 2 5 Discharge Pond 5 MPP 3 6 Discharge Pond 4 3 CO2 Capture and Compression Section Page 24
- 25. Cooling Water • Cooling water can be branched off from manholes of seawater cooling system MPP3 • Cooling water discharge routed to MPP3 siphon-pit Page 25
- 26. Agenda • Project overview • Main interfaces • • • • Flue Gas tie-ins Steam/condensate supply Electric supply Cooling water • Other interfaces • Operation and emissions • Lessons learned 26 Page 26
- 27. Utilities* • Demineralized water : ~10 t/h supply from MPP3; valve installed • Potable, rain and sewage water connect to MPP3 closest MPP3 tie-in points • DCC flue gas condensate : ~44 t/h to Process Water Tank/FGD MPP3 • Deep FGD condensate : ~0,4t/h cooling water discharge • Fire fighting water combined with MPP3 system * (all values estimated for design case) Page 27
- 28. Agenda • Project overview • Main interfaces • • • • Flue Gas tie-ins Steam/condensate supply Electric supply Cooling water • Other interfaces • Operation and emissions • Lessons learned 28 Page 28
- 29. Operating Window Capture Plant 100% Load MPP3 Carbon Capture 25% 0% 0% 40% Flue Gas Flow Capture Plant 100% 700 500 m3/h Page 29
- 30. Carbon Emissions: Effects of CCS and Co-firing Biomass Page 30
- 31. Agenda • Project overview • Main interfaces • Flue Gas tie-ins • Steam/condensate supply • Electric supply • Cooling water • Other interfaces • Operation and emissions • Lessons learned 31 Page 31
- 32. Lessons Learned • Low redundancy and low engineering margins make CCS more economical • Heat integration can save both CAPEX and OPEX • Steam jet boosters may be economical for part load power plant situations to ensure enough pressure for reboiler steam of capture plant • Further heat integration for 100% capture will require external consumers with low temperature demand • Condensate retrieved in Direct Contact Cooler (DCC) can be used as process water in power plant and almost eliminate external fresh water supplies Page 32
- 33. Thank You For Your Attention! Questions? Page 33
- 34. QUESTIONS / DISCUSSION Please submit your questions in English directly into the GoToWebinar control panel. The webinar will start shortly.
- 35. Please submit any feedback to: webinar@globalccsinstitute.com Full report available: http://www.globalccsinstitute.com/publications/integration-capture-plantand-power-plant-road