WP3 Scale-up and Engineering CCL Pilot Plant · • GE Boiler Deutschland GmbH, Stuttgart/Germ. • Alstom Power Inc., Windsor- CT/USA GECC ... –Fixed calculation basics (e.g. plant

Imagination at work

WP3 – Scale-up and Engineering for a 20 MWth CCL Pilot Plant 1st Public SCARLET Workshop

Darmstadt, 20th April 2016

Christoph Weingärtner, GE Carbon Capture GmbH All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Definition & Motivation

© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016

Definition & Motivation

Definition – What do we intend to?

In WP3 it is planned to scale up, design and engineer a 20 MWth field CCL pilot plant for CO2 separation from power plants with limestone, based on results from preceding WP1 and 2

Motivation – Why do we do it?

Construction of a pilot plant in the order of 20 MWth is a logical next step in the development and scale-up of this technology

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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”

Objectives & Methodology


Objectives

• Definition of the CCL technology process configuration for a 20 MWth pilot plant, based on the location of the host facility. Site selected as host for this study is the 600 MWe Emile Huchet coal-fired power plant operated by Uniper in France.

• Design and engineering of the components of the 20 MWth pilot plant concluding in a CAPEX and OPEX cost estimation

• Investigation of Balance of Plant and evaluation of the permitting process for erection and operation of the pilot plant

• Definition of a detailed plan for operation and logistics

• HSE and technical risk assessment for the CCL pilot will be jointly conducted

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Methodology

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Team Members & Tasks


WP Team Members

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Name Location Main Contribution

GE Carbon Capture GmbH with 3rd parties: • GE Boiler Deutschland GmbH, Stuttgart/Germ. • Alstom Power Inc., Windsor- CT/USA

GECC Wiesbaden/ Germany

WP LEAD Engineering of process gas side and solids installations

Technische Universität Darmstadt TUD Darmstadt/ Germany

Perform process simulations to calculate Heat & Mass balances for each selected operation point Contribute experience from 1 MW CCL pilot

Steinmüller Babcock Environment GmbH SBE Gummersbach/ Germany

Engineering of steam/water side (heat recovery) and gas side filtration

Centre for Research and Technology Hellas

CERTH Thermi/ Greece

Support the simulations of the reactors with validated CFD models

Uniper Technologies Limited with 3rd parties: • Uniper Technologies GmbH, Germany • Uniper France Power S.A.S

UNP Nottingham/ UK

Investigate the Balance of Plant and evaluate the permitting process for erection and operation of the pilot plant

SWR Engineering Messtechnik GmbH SWR Schliengen/ Germany

Develop/improve a concept of a measuring system for online detection for solids mass flow and cost estimate

Lhoist Recherche and Development SA LRD Nivelles/ Belgium

Provide specification and logistics of sorbent


WP Tasks

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No. Task Main items Partners (Lead)

Period

3.1 Process Definition

• Provide Basis of Design and boundary conditions of host plant for the CCL pilot plant design

• Define process configuration & control concept in Process Flow Diagrams (PFDs) and Process description

GECC, SBE, TUD, UNP

M15-25

3.2

Definition of Nominal

Operation Conditions

• Define test program for various operation points

• Calculate heat & mass balances for each operation point based on validated simulation tools from WP1/2

GECC, SBE,

TUD, M21-30

3.3 Planning of Measurements

• Work-out of detailed plan of measurements GECC, SBE, TUD

M25-30

3.4

Improved Concept of Measuring System for Solids Mass Flow

• Develop/improve a concept of a measuring system for online detection for solids mass flow and cost estimate

SWR M25-30

3.5 Design of

Reactors and Auxiliaries

• Design major CCL reactor system components incl. auxiliaries; CAD drawings of reactors

• Investment cost estimate • 3D CFD simulation of reactors

CERTH,

GECC, TUD M25-33

Green = Tasks started


WP Tasks (continued)

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Period

3.6 Design of Water/Steam Cycle

• Engineer heat recovery to the water/steam cycle and gas side filtration; CAD drawings

• Investment cost estimate SBE, TUD M25-33

3.7

Design of Coal, Sorbent , O2

Supply & CO2 Purif. Systems

• Engineer coal, sorbent , O2 supply & CO2 purification systems

• Provide process specification for O2 supply package

• Investment cost estimate • Specification of sorbent

GECC, LRD,

TUD M25-33

3.8

Definition of normal op./start-up/shut-down procedures

• Define normal op./start-up/shut-down procedures • Simulation of dynamic behavior with unsteady state

model

GECC, SBE, TUD

M25-36

3.9 Planning of Logistics

• Planning of supply of consumables/utilities + disposal of

residuals • Investment cost estimate • Specification of sorbent

GECC, LRD, UNP

M25-33

3.10 Process and Instrumentation Diagrams

• Define process instrumentation incl. analytical equipment and control loops

• Determine required sizes for major piping/ducts • Develop basic P&IDs

GECC, SBE, TUD

M25-33


WP Tasks (continued)

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Period

3.11 Layout Planning • Develop plant layout arrangement and 3D CAD model

(Artist view) GECC, SBE, TUD

M28-33

3.12 Health and Safety Risk Assessment

• Identify potential health and safety risks by conducting a Process Hazard analysis with Hazard Study 1 methodology

• Elaborate a risk mitigation plan

GECC, SBE, TUD, UNP

M22-26

3.13 Technical Risk Assessment

• Carry out a technical risk analysis based on Failure mode criticality analysis

GECC, SBE, TUD

M27-30

3.14 Determination of Costs

• Estimate investment , operational and maintenance cost GECC,SBE, TUD, UNP

M33-36

3.15 Permission Actions

• Evaluate the process to obtain required permissions for erection and operation from authorities in France

UNP M25-36

Current Status


Current Status

Task 3.1 Process Definition

• Basis of Design (BoD) Document has been set up

– Fixed calciner heat duty at approx. 10 MWth

– Defined two hard-coals representing expected coal range (El Cerrejon as design coal and Pittsburg No. 8 as high sulfur coal)

– Fixed CO2 Product quality (EOR specification) & CO2 Product logistics (back to stack)

– Fixed calculation basics (e.g. plant life time, operating time, etc)

• Process concept & configuration / Process Flow Diagram (PFD): Draft PFD developed and screened, depicting the process configuration and control loops

• Host site visited; planned plot area and integration/tie-in locations established

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Current Status

Task 3.2 Definition of Nominal Operation Conditions

• 1st preliminary heat & mass balance for Design Case developed

Task 3.12 Health and Safety Risk Assessment

• Potential health and safety risks identified by conducting a Process Hazard analysis with Hazard Study 1 methodology (HAZID)

• Risk mitigation plan under development

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Process Concept

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Host site & integration of 20 MWth CCL pilot

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600 MWel Unit 6 of Emile Huchet coal-fired power plant operated by Uniper in Saint-Avold/France


Photograph by courtesy of Uniper


Host site & integration of 20 MWth CCL pilot 17




Host site & integration of

20 MWth CCL pilot

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Site plan by courtesy of Uniper

600 MWel Unit 6 of Emile

Huchet coal-fired power

plant operated by Uniper

in Saint-Avold/ France



Retrospect to LISA II P1 (LISA 20, BmWi COORETEC)

3D Model Plant Layout of a

20 MWth CCL Pilot plant

• Plant features also CO2 purification, Oxygen and CO2 storage

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Short outlook to further work


Short outlook to further work

Task 3.1-3.15

• Process concept will be finalized and H&MB generation for scaled-up pilot will be done after test results from test campaign #1 are evaluated in WP1 and process models developed have been successfully validated in WP2 against test data.

• Core engineering tasks of WP3 like equipment design, preparation of P&ID, etc. will be started after finalization of H&MB.

• All activities are planned to be started according to overall project schedule with majority of engineering activities expected to start in May 2016.

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Contact Christoph Weingärtner Technology Manager RCC GE Power Steam Power Systems T +49 6134 712 284 M +49 1706 355 590 [email protected] www.ge.com

© 2016 General Electric Company. Proprietary. All Rights Reserved.

WP3 Scale-up and Engineering CCL Pilot Plant · • GE Boiler Deutschland GmbH, Stuttgart/Germ. • Alstom Power Inc., Windsor- CT/USA GECC ... –Fixed calculation basics (e.g. plant

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