large pilot scale testing of linde/basf post … · 2015. 10. 1. · project essentials doe‐netl...
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LARGE PILOT SCALE TESTING OF LINDE/BASF POST‐
COMBUSTION CO2 CAPTURE TECHNOLOGY AT THE ABBOTT COAL‐FIRED
POWER PLANT
Phase I Kick‐off MeetingDecember 10, 2015
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Objectives
• Design and install a carbon capture system of nominal 25 MWe – Integrate with the Abbott Power Plant flue gas system– Demonstrate the viability of continuous operation under realistic conditions
with high efficiency and capacity– Optimize the process at this scale and to gather performance data to enable a
robust design of large commercial size plants
• Provide a guideline for the retrofit of other existing plants within the coal fleet– Enable future knowledge sharing with other utilities in order to
encourage and facilitate the retrofit process
• Illustrate a path forward for the utilization of the captured CO2
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TECHNOLOGY DESCRIPTION
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BASF OASE® blue technology developmentLinde adopted and optimized for PCC applications
—2001, Ludwigshafen—Solvent performance verification
—2009, Niederaussem—Process optimization, materials testing
—2014, Wilsonville, AL—Design improvements, emissions confirmation
—2017/18, proposed—PCC plant cost reduction—Full value chain
Equilibria
Kinetics
Stability
Mini plant Pilot: 0.5MWe Pilot: 1.5 MWe Large Pilot: 25 MWe
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Niederaussem PCC Pilot PlantOperational experiences and main results
Even after six months of operation, the oxidation rate of OASE® blue was extremely low
A2
B1
B2
B6
B3
B4
B5
B7
B8A3
A1 A5
A4
A6
A1, A3 – A6:Flanges, tubes, gaskets
A2:Concrete module
B1 – B8:Coupons
Pre-scrubber
AbsorberDesorber
Causticsoda
Drain
Make-up waterCO2-leanflue gas
CO2 fromregeneration
Drain
Solvent
Flue gas
OASE® blue has a 20% lower specific energy consumption OASE® blue has a
significantly lower solvent circulation rate
OASE® blue was tested over 26,000 hours (> 3 years) nearly 21,000 t CO2 were
captured with OASE® blue
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Niederaussem PCC Pilot PlantEmission reduction measures – "Dry bed"
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0 4 8 12 16 20 24 28 32 36
Amin
e C
once
ntra
tion
in F
lue
Gas
Ab
sorb
er T
op
Time [h]
Amine traces downstream water wash
Applicationof the "Dry Bed"
Return to normal operation
Reduction of amine emissions by an order of magnitude: Proprietary process configuration „Dry Bed“
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Wilsonville PCC Pilot PlantProject essentials
DOE‐NETL funded project ($16.2 million funding) Total project cost $22.7 million Location: 880 MWe Gaston Power plant (operated by
Southern Co.) in Wilsonville, AL Site of the National Carbon Capture Center Capacity: Up to 6,250 Nm3/h flue gas from coal fired
power plant (30 t/d CO2); Up to 1.5 MWe CO2 purity 99+ vol % (Dry basis) Project start: November 2011 Start‐up: January 2015 Project Duration: 4.5 years Partners: Linde LLC, Linde Engineering North America,
Linde Engineering Dresden, BASF, DOE‐NETL, EPRI, Southern Company (Host site)
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Wilsonville PCC Pilot Plant Typical result for specific energy consumption
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Wilsonville PCC Pilot Plant Plant performance against targets
PerformanceAttribute
Current achievement against target
Remarks
1. CO2 capture rate >90% per target Achieved. Optimized for specific energy.
2. CO2 purity 99.9% dry basis per target Achieved. Low O2 impurity level for EOR applications demonstrated.
3. Plant capacity > 1.5 MWe per design target (>15,500 lbs/hr flue gas)
Achieved. Higher capacity testing performed ~10 days in May‐June and repeated in Nov 2015
4. Regenerator steam consumption
~ 2.8 GJ/tonne CO2 (same as Niederaussem consumption)
Energy optimization continued.
5. Emissions control validation
Validation of dry bed (BASF patented) operation per design
Emissions control optimization performed with special isokinetic sampling & analysis.
6. Regenerator operatingpressure
Testing performed up to 3.4 bars and higher pressure performance validated
Parametric tests to compare optimum performance at different pressures from 1.6 to 3.4 bars in progress
7. Validation of unique features
(i) high capacity packing, (ii) gravity driven intercooler, (iii) blower downstream of abs.(iv) unique reboiler design.
Optimization of lean‐rich heat exchanger for energy reduction during next campaign
Note: Regenerator steam consumption above is intrinsic and does not include process and heat integration
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25 MWe coal‐fired flue gas (500 TPD CO2) Located at Abbott Power Plant, Champaign, IL ; Host site: University of Illinois 35 MWe cogen plant
US DOE funding: $1 million; Phase 1 Project definition in progress (Q4 2015 – Q3 2016)
Phase 2 proposal & selection in Q3/Q4 2016
Large pilot development at University of IllinoisProject essentials
LARG
E PILO
T
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Illinois PCC Large Pilot Plant Technology features
Solvent regeneration CO2-capture Flue gas cooling, SO2-pre scrubbing
CO2
Desorber
Flue gas
Absorber
Prescrubber
Booster fan
Condenser
Filter
Reboiler
CO2-lean flue gas
Steam
Make-up water
Interstage cooler
NaOH solution tank
Solvent tank
Solvent
Condensate
New Reboiler Design
Process Optimization
Optimized Emission Control System
Blower Position Adjusted to Local Requirements
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PROJECT MANAGEMENT
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Project Organization Chart
University of Illinois
Linde LLC
BASF
Linde Engineering Dresden, GmbH
Germany
Linde Process Plants, Tulsa OK
Affiliated Engineers
Sargent Lundy, LLC
Advisory Board
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Phase I Funds
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Team Roles & Responsibilities for Physical Infrastructure
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‐ AEI , Sargent & Lundy
‐ Linde, BASF
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Key Personnel
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Organization Role Key Personnel
University of Illinois Host Site / Technology Evaluation Dr. Kevin C OBrienDr. Yongqi Lu
The Linde Group Technology Developer, ISBL Engineering, Procurement, Construction
Dr. Krish KrishnamurthyDr. Joseph Naumovitz
BASF Technology Developer, basic design and solvent management
Dr. Sean Rigby
Affiliated Engineers OSBL Engineering David Guth, LEED AP
Sargent Lundy, LLC OSBL Procurement, Construction Kevin Lauzze, P.E.
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Roles & Responsibilities Mapped to WBS
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WBS # WBS Title Scope Summary
UI
Lind
e
SL AEI
BASF
1.0 Project Management and Planning
1.1 Project Monitoring & Controls
Ensure project coordination and planning with DOE/NETL and participants.
X
1.2 Briefings, Reports and Conferences
X X X X X
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Roles & Responsibilities Mapped to WBS
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WBS # WBS Title Scope Summary
UI
Lind
e
SL AEI
BASF
2.0 Technology Engineering Design and Economic Analysis
2.1Basis and Scope for thePower Plant with CO2Capture
Define the system boundaries and process design assumptions according to the specified DOE‐NETL methodology
X
2.2Detailed Design of thePower Plant with Post‐Combustion Capture
Update the detailed design of major equipment per specified NETL report
X
2.3Economic Analysis of thePower Plant with CO2Capture and Compression
Prepare cost estimates of all the major equipment per specified NETL report
X
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Site for Carbon Capture Plant EstablishedLocated close to Abbott Power Plant
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Layout of Linde’s Carbon Capture Plant200 ft. x 200 ft. footprint
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Integration of PCC Plant with Power Plant Interface and Tie‐In Points
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PCC Pilot Plant Integration with Power Plant with Utilities
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Steam
Steam Steam for Power Campus HeatDemin Makeup Water
CO2Flue gas
cooling water
condensate
condensate return
Boiler # 5STG‐6
25 MWe PCC plant
Boiler # 6
STG‐7
Steam Header
Cooling Tower
Existing unit
New unit
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Roles & Responsibilities Mapped to WBS
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WBS # WBS Title Scope Summary
UI
Lind
e
SL AEI
BASF
3.0 Environmental, health and safety (EH&S) Risk Assessment
3.1 Preliminary EH&S Analysis X X X
3.2 Phase II EnvironmentalQuestionnaire
Prepare Environmental Questionnaire for the Phase II project based on the results from the EH&S assessment
X
3.3Determine environmentalpermitting requirements and prepare documentation
Determine the permitting requirements for CO2 capture at the existing power plant.
X
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Roles & Responsibilities Mapped to WBS
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WBS # WBS Title Scope Summary
UI
Lind
e
SL AEI
BASF
4.0 Technology Gap Analysis and Risk Management
4.1 Technology GapIdentification
Identify the impact of technology scaling gaps and assess their impact on performance.
X X
4.2 Risk Mitigation PlanningEvaluate the impact of key design parameters and options to mitigate the risk
X
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Roles & Responsibilities Mapped to WBS
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WBS # WBS Title Scope Summary
UI
Lind
e
SL AEI
BASF
5.0 Design, Engineering and Costing of the Large Pilot Plant
5.1 Design Basis Definition Identify any modifications required at Abbott for CO2 capture system. X X X
5.2 Large Pilot Plant Designand Engineering
An engineering package of the capture system integrated with the power plant will be developed.
X X X X
5.3 Large Pilot Plant Costing
A detailed estimate of the overall capex of the large pilot as well as plant consumables and O&M labor will be compiled.
X X
6.0 Phase II Application Preparation
Prepare a Phase II proposal compliant with NETL / DOE guidelines listed in DE‐FOA‐0001190
X
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Project Timeline and Milestones
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Milestone Log
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Budget Period ID Task
Number Description Planned Completion Date
Actual Completion
Date
Verification Method
1 a 1 Updated Project Management Plan 10/1/2015
Project Management
Plan file
1 b 1 Kickoff Meeting 12/30/2015 Presentation file
1 c 2 TEA Completed 03/31/2016 Presentation file
1 d 3 EH&S Study Completed 03/31/2016 Presentation
file
1 e 5 Phase 1 Topical Report Completed 3/31/2016 Presentation
File
1 f 1 Host Site Agreement Completed 06/30/2016 Signed
agreement
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Overview of Project Schedule
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Technical Risks & MitigationDescription of Risk Probability Impact Risk Management
Mitigation and Response StrategiesScale‐up risk: Vapor and liquid mal‐distribution in the absorber column
Low Medium‐High Leverage Linde experience in designing other large columns
A model will be used to predict the distribution of fluids in the column
Solvent‐related issues (corrosion, adequate supply, handling)
Low Medium‐High BASF expertise and testing experience from 0.5 and 1.5 MWe pilot plants
BASF confirmation of solvent supply Use data from corrosion coupon testing that was
performed at 1.5 MWe scaleEmissions and waste streams, including unknown contaminants
Low‐Medium Medium Leverage testing experience from 0.5 and 1.5 MWe pilot plants
Confirm dry bed configuration for emissions control at large scale
Detailed analysis (including heavy metals) of flue gas and liquid streams
Integration with operations at the Abbott plant
Low Medium Joint meetings to understand issues and incorporate into design, control logic, and operations plan
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Resource Risks & Mitigation
Description of Risk Probability Impact Risk Management Mitigation and Response Strategies
Flue gas and utilities non‐availability from power plant
Low High Past experience is favorable. Work with Abbott to confirm no issues with flue gas and utility availability
Coordinate with Abbott plant to meet both Abbott production and pilot project requirements
Pilot plant design basis to be set based on specification of the flue gas and utility requirements, and confirmation from Abbott on availability
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Management Risks & MitigationDescription of Risk Probability Impact Risk Management
Mitigation and Response StrategiesUncertainty of time required of obtaining environmental permits
Moderate High Detailed and thorough preparation work in Phase I;
Close communication with IEPA; Include IEPA as a board member to follow
project progress; Involve professional compliance consulting
company to accelerate preparation and application
Uncertainty of time required for NEPA documentation especially if an Environmental Impact Statement (EIS) is determined to be required
Moderate High Involve professional environmental impact assessment personnel in the team;
Involve environmental consulting companies;
Experience and lessons from other projects with similar scale
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HOST SITE DESCRIPTION
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Host Site: Abbott Power Plant
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• Seven boilers total: three are coal based (Chain‐grate stoker design) others natural gas
• Coal side has completely separate treatment system from natural gas side
• For testing will run two coal boilers• Illinois high sulfur coal is burned• Electrostatic precipitators and a wet Flue
Gas Desulfurizer (FGD) in place• Tradition of evaluating new emission
technologies• Tradition of showcasing technologies to
other power plants and education groups
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ENABLING THE PROPAGATION OF CCUS: ADVANTAGES OF A UNIVERSITY TEST SITE
• Educational site for industry & students• Facilitating future utilization approaches
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Advisory Board for Capture ProjectKey partnerships regionally and with China, India, and Brazil
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Regional & Global Test Bed for CCUSConcentration of natural resources and intellectual capital
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Decatur
Champaign‐Urbana
Mattoon
Carbondale
Fairfield,Olney, Robinson, Mt.
Carmel
• Operator Training
• Coal combustion
• Utilization of CO2 : Enhanced Oil Recovery (EOR)
• Storage of CO2 : ADM Project
• Capture of CO2 : Abbott Power Plant UIUC