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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
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
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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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Methodology
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
Team Members & Tasks
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
WP Team Members
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
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
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
WP Tasks
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
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
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
WP Tasks (continued)
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
No. Task Main items Partners (Lead)
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
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
WP Tasks (continued)
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
No. Task Main items Partners (Lead)
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
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
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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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
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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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Process Concept
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
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
WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
Photograph by courtesy of Uniper
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Host site & integration of 20 MWth CCL pilot 17
Photograph by courtesy of Uniper
WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Host site & integration of
20 MWth CCL pilot
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
Photograph by courtesy of Uniper
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Host site & integration of 20 MWth CCL pilot
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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
Site plan by courtesy of Uniper
600 MWel Unit 6 of Emile
Huchet coal-fired power
plant operated by Uniper
in Saint-Avold/ France
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
Host site & integration of 20 MWth CCL pilot
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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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
Short outlook to further work
© General Electric Company and/or its Affiliates, 2016. SCARLET 1st Public Workshop | 20. April 2016
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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WP3 “SCALE-UP AND ENGINEERING FOR A 20 MWth CCL PILOT PLANT”
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.