01 POWER ISLAND / 04 CO2 capture / ROAD - FEED study -final-high-res-figures

Maasvlakte"CCS"Project"C.V."

2.Introduction-to-FEED-study-report-

In"July"2009,"Maasvlakte"CCS"Project"C.V."(‘MCP’)"submitted"its"project"proposal"to"the"European" Commission," to" apply" for" funding" under" the" framework" of" the" European" Energy" Program" for" Recovery" (‘EEPR’)." This" marked" the" start" of" the" ‘ROAD" project’" (‘Rotterdam" Opslag" en" Afvang" Demonstratieproject’;"Rotterdam"Storage"and"Capture"Demonstration"project).""

2.1Developing-the-ROAD-project-

In" this" report," the" results" of" the" front:end" engineering" design" (‘FEED’)" study" for" the" capture" plant"as"performed"by"Fluor"will"be"summarized."This"FEED"study,"however,"was"only"part"of"the" work"performed"on"the"ROAD"project"during"its"development"phase."In"parallel,"various"other" activities" were" executed" to" develop" the" project" to" such" an" extent" that" the" final" investment" decision"could"be"taken"by"the"end"of"2011."This"section"aims"to"show"the"project"development" context" within" which" the" FEED" studies" were" performed" by" two" competing" suppliers" (see" also" [1])." It" will" briefly" introduce" the" reader" to" phased" project" development" approaches," with" the" framework" developed" by" the" Global" CCS" Institute" taking" a" central" role" [2]." Subsequently," a" rough"sketch"of"the"activities"performed"by"ROAD"in"parallel"with"the"FEED"study"is"provided.""

2.1.1Project-development-framework-

Using" a" structured" stage:gated" project" management" process" is" generally" identified" as" a" key" factor"in"successfully"delivering"capital"expenditure"projects."An"information:driven"stage:gated" process"facilitates"a"logical"sequence"of"project"development"activities,"ensuring"that"all"relevant" information"is"available"in"time"and"that"all"important"issues"are"resolved"before"further"steps" are"taken"[3]."Such"a"process"is"generally"applied"within"both"mother"companies"of"Maasvlakte" CCS"Project"C.V.""

"

The"Global"Carbon"Capture"and"Storage"Institute"is"currently"developing"a"project"development"

framework"that"is"tailored"for"the"development"of"CCS"projects."The"framework"comprises"three"

levels:"

•On"the"highest"level,"six"stages"in"the"development"of"a"CCS"project"are"defined,"fully" aligned"with"oil"and"gas"industry"standard"practice:"identify,"evaluate,"define,"execute," operate"and"closure."For"each"of"these"phases"the"generic"approach,"actions"to"be"taken" and" goals" to" be" achieved" are" set" out" on" one" A3" page." This" is" done" for" the" project" in" general" and" for" each" of" the" three" steps" in" the" CCS" value" chain" (capture," transport," storage).""

•On" the" second" level," an" overview" is" provided" of" around" 20" relevant" topics" specific" to" each"of"the"three"steps"in"the"CCS"value"chain,"setting"out"the"relevant"steps"to"be"taken" on"each"of"the"topics"in"each"of"the"six"development"phases.""

•On"the"third"level,"the"actions"proposed"to"be"taken"on"the"second"level"are"elaborated.""

"

The"current"draft"of"the"highest"level"framework"as"well"as"the"current"version"of"the"second" level"document"focusing"on"capture"can"be"found"in"the"annexes"to"this"report.""

2.1.2ROAD-–project-development-status-during-“define”-phase-

Phrased"in"terms"of"the"Global"CCS"Institute’s"CCS"project"development"framework,"ROAD"is"at" the" time" of" writing" this" report" in" its" “define”" stage;" the" last" phase" before" execution" of" the" project"starts."As"the"phase’s"name"suggests,"the"define"phase"is"focused"on"defining"the"project" to" such" an" extent" that" a" final" investment" decision" can" be" taken" based" on" the" available" information." In" this" phase" the" technical" and" economic" viability" of" a" project" needs" to" be" demonstrated." Basic" engineering" (FEED" study)," cost" estimating," contractor" selection" and" permitting"are"the"key"activities"in"this"phase"of"the"project.""

"

Maasvlakte"CCS"Project"C.V."

2.2.4Stakeholder-management-

In" the" report" on" stakeholder" management" [7]" ROAD’s" major" stakeholders" will" be" identified." These"include"permitting"authorities,"local,"national"and"EU"government"bodies"and"the"public." Stakeholder"management"will"be"described"in"general"and"public"outreach,"permitting"and"the" regulatory"process"will"receive"particular"attention."

2.2.5Execution-strategy-

ROAD’s"project"execution"strategy"will"be"described"in"the"special"report"on"execution"strategy"

[8]."This"report"will"contain"for"example"a"high"level"project"schedule,"organizational"structure"

and"discussions"on"execution"related"aspects"of"the"environmental"impact"assessment,"

contracting,"finance"and"stakeholder"management.""

2.3Structure-of-report-

The"structure"of"this"report"on"the"winning"FEED"study"for"ROAD’s"capture"plant"is"as"follows:""

•Chapter"3"describes"the"capture"FEED"scope"and"boundaries"

•Chapter"4"describes"the"process"of"the"capture"plant"and"the"compression"

•Chapter"5"describes"the"health,"safety"and"environmental"issues""

•Chapter"6"describes"the"CO2"stream"

•Chapter"7"describes"financial"and"scheduling"aspects"of"capture"plant"and"compressor."

"

Maasvlakte"CCS"Project"C.V."

3.Capture-FEED-scope-and-boundaries-

The"ROAD"project"has"selected"a"final"supplier"for"the"capture"plant"based"on"multiple"rounds"of" studies."The"capture"FEED"study"phase"was"one"of"these"rounds."The"complete"description"of" the"selection"procedure"can"be"found"in"the"capture"technology"selection"report"[1]."

As"starting"point"of"each"round,"the"supplier"received"a"technical"specification"from"the"ROAD" project." In" this" description," the" project" was" explained" and" boundary" conditions" and" quality" standards"to"be"implemented"in"the"study"phase"were"submitted."

The" result" was" a" very" detailed" document," of" over" 150" pages," excluding" appendices." In" this" chapter"the"main"issues"are"highlighted."

3.1.1Power-plant-MPP3-

The" capture" suppliers" were" given" information" on" MPP3" with" more" details" on" the" general" installation:"

Base!installation:!E.ON!Maasvlakte!Power!Plant!3!(Rotterdam,!The!Netherlands)!

•Capture!ready!

Besides" power" plant" data," also" information" on" general" aspects" like" weather" conditions," surroundings"and"soil"investigations"was"provided."

3.1.2Capture-plant-design-

In"the"specification"the"design"philosophy"was"described"with"this"statement"as"main"message:"

The!capture"plant!process!design!should!be!optimized!to!minimize!through!life!cycle!costs!of!the! project,!balancing!capital!costs!against!reduced!power,!steam!and!utilities!consumption!without! compromising!plant!design!performance,!availability!and!operability.!The!design!should!also!be! sufficiently!flexible!to!enable!stable!operation!at!reduced!flue!gas!flow!and!a!rapid!response!to! change!in!flue!gas!inlet!conditions.!

As"this"demonstration"project"is"expected"to"be"a"loss"making"project,"the"aim"is"not"to"have"the"

highest"possible"availability,"but"to"seek"a"balance"between"costs"and"plant"performance."

3.1.3Soil-situation-

An"example"of"the"specifications"given"to"the"supplier"is"the"soil"profile:"

The!general!soil!profile!at!the!site!is!as!follows:!

•Groundwater!level!at!ca.!+!2m!NAP!(Normaal!Amsterdams!Peil,!reference!of!height)!

•Loose! to! densely! compacted! sand! with! local! laminations! of! clay! from! surface! level! to! level!%20!m!NAP!

•1st!clay!layer!from!level!%20!m!to!%22!m!NAP!

•Densely! compacted! sand! from! below! ca.! %22! m! NAP! (used! as! bearing! level! for! MPP3! power!island!piles)!

•2nd!clay!layer!at!ca.!–!40!m!NAP!

•Densely!compacted!sand!below!2nd!clay!layer!

"

By"providing" such"detailed" information" the" capture" plant" supplier"was"in" the" best" position" to" design"a"capture"plant"according"to"ROAD´s"wishes.""

Maasvlakte"CCS"Project"C.V."

4.Capture-and-compression-process-

In"this"chapter"the"capture"and"compression"process"are"described."The"information"is"based"on"

the"FEED"study"carried"out"by"the"winning"FEED"supplier."The"information"given"in"this"report"is"

non:confidential,"but"can"still"be"valuable"to"assess"the"process.""

4.1Process-description-of-capture-and-compression-

This"section"provides"the"process"description"for"the"Econamine"FG"PlusSM"(EFG+)"CO2"capture" and" compression" plant" for" the" ROAD" project." The" purpose" of" the" proposed" EFG+" plant" is" to" recover" 90%" of" the" total" CO2" available" in" a" 250" MW:equivalent" slip" stream" of" flue" gas" from" Maasvlakte" Power" Plant" 3" (MPP3)," a" 1,070" MW" (net" electric)" advanced" supercritical" power" plant." The" EFG+" Plant" produces" approximately" 4,057" t/day" of" CO2" (dry" basis)" that" will" be" compressed"and"sent"to"the"EFG+"plant"battery"limit"to"be"transported"through"a"pipeline"to"off: shore"storage"in"the"North"Sea."

In" Appendix" 2" the" Process" Flow" Diagrams" can" be" found," please" refer" to" this" appendix" for" the" codes"in"the"description"below."

4.1.1Flue-gas-cooling-and-trim-SOX-removal-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"43.""

The" flue" gas" feed" to" the" EFG+" plant" comes" from" the" Flue" Gas" Desulfurization" (FGD)" unit" of" MPP3."Flue"gas"from"the"FGD"unit"is"first"routed"to"the"Direct"Contact"Cooler"(DCC)"(3"0HKB10" BB001)" for" both" cooling" and" trim" SOX" removal." The" flue" gas" cooling" is" done" in" the" quench" section"of"the"DCC"by"circulating"water."Circulating"water"is"drawn"from"the"bottom"of"the"DCC" to"the"DCC"Water"Cooler"(30HKB30"AC001/2)"by"DCC"Circulation"Pump"(3"0HKB20"AP001/2)"and" returned" to" the" top" of" the" column’s" quench" section." The" circulating" water" is" heated" by" the" cooling"and"condensing"of"water"vapor"in"the"flue"gas."

Excess" water" produced" in" the" DCC" from" the" condensing" of" water" vapor" in" the" flue" gas" is" neutralized"using"20"wt%"NaOH."The"neutralized"excess"water"stream"is"held"temporarily"in"the" DCC"Water"Neutralization"Tank"(3"0HKB50"BB001)"and"sent"to"the"plant"battery"limit"using"the" DCC"Excess"Water"Pump"(3"0HKB60"AP001)."Cooled"flue"gas"from"the"quench"section"of"the"DCC" contacts"a"circulating"scrubbing"solution."The"scrubbing"solution"is"circulated"to"the"top"of"the" column" by" DCC" Scrubbing" Solution" Pump" (3" 0HKE70" AP001/2)." A" 20" wt%" sodium" hydroxide" (NaOH)"solution"supplied"by"the"DCC"NaOH"Injection"Pump"(3"0HKE60"AP001/2),"along"with"a" slip" stream" of" cooled" DCC" water" taken" downstream" of" the" DCC" Water" Cooler," are" fed" to" the" suction" of" the" DCC" Scrubbing" Solution" Pump." A" blowdown" slip" stream" is" taken" from" the" circulating" scrubbing" solution" loop" which" could" be" used" as" make:up" to" the" power" plant" after" treatment."The" cooled," desulfurized" flue" gas" passes" through" a"mesh" mist" eliminator" and" exits" the"top"of"the"column"where"it"is"routed"to"the"Blower"(3"0HKC10"AN001)."The"20"wt%"sodium" hydroxide"solution"is"made"by"diluting"a"50"wt%"NaOH"stock"solution,"which"is"stored"in"50"wt%" NaOH"Storage"Tank"(3"0HKE20"BB001)"using"demineralized"water."

4.1.2Flue-gas-blower-and-CO2-absorption-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"43.""

The" Blower" (3" 0HKC10" AN001)," located" downstream" of" the" DCC," is" used" to" overcome" the" pressure"drop"through"the"EFG+"plant."From"the"Blower,"the"flue"gas"enters"the"bottom"of"the" Absorber"(3"0HKD10"BB001)"and"flows"upward"through"the"packed"column"beds,"where"it"reacts" with"the"EFG+"lean"solvent."A"total"draw"of"semi:rich"solution"is"extracted"from"the"column"and" sent"by"the"Absorber"Intercooler"Pump"(3"0HKD20"AP001/2)"through"the"Absorber"Intercooler" (3" 0HKD30" AC001:3)" where" the" solution" is" cooled" before" being" returned" to" the" Absorber." Treated" gas" from" the" absorption" section" enters" the" wash" section" at" the" top" of" the" Absorber"

Maasvlakte"CCS"Project"C.V."

where" EFG+" solvent" in" the" vapor" phase" is" captured" by" a" circulating" wash" water" loop." Wash" water"is"drawn"from"the"bottom"of"the"wash"section"and"sent"through"the"Wash"Water"Cooler" (3" 0HKD50" AC001/2)" by" Wash" Water" Pump" (30HKD40" AP001/2)." Demineralized" water" is" also" added" to" the" top" of" the" column"which" removes" any" entrained" solvent" and" reduces" the" vapor" phase"solvent"in"the"exiting"flue"gas."

The"treated"flue"gas"is"then"routed"through"a"mesh"mist"eliminator"and"is"returned"to"the"stack"

of"MPP3."Excess"water"from"the"wash"water"section"is"combined"with"lean"solvent"entering"the"

Absorber"above"the"amine"packed"bed."

4.1.3Solvent-regeneration-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"44.""

The"rich"solvent"leaves"the"bottom"of"the"Absorber"and"is"pumped"by"the"Rich"Solvent"Pump"(3"

0HKG10"AP001/2)"to"the"solvent"regeneration"section"of"the"EFG+"Plant."Rich"solvent"from"the"

Absorber"is"routed"to"the"Solvent"Cross"Exchanger"(30HKG20"AC001:12)"to"heat"the"rich"solution" against"the"lean"solution"from"the"Lean"Flash"Drum"(3"0HKH30"BB001)."The"hot"rich"solvent"then" enters"the"Stripper"(30HKH10"BB0010)."

Rich" solvent" flows" down" the" Stripper" through" the" packed" beds" counter:current" to" stripping"

steam,"which"removes"CO2"from"the"rich"solvent."Solvent"collects"on"the"bottom"chimney"tray" and" is" sent" to" the" Reboiler" (3" 0HKH20" AC001:6)." Heat" input" to" the" Reboiler" is" provided" by" condensing"low"pressure"(LP)"steam."In"the"wash"section"of"the"Stripper"above"the"feed"nozzle," water"from"the"Overhead"Accumulator"(3"0HGA20"BB001)"is"used"to"wash"entrained"solvent"out"

of" the" vapor"stream." The" resulting" vapor" from" the" top" of" the" Stripper" contains"CO2"saturated" with"water."The"vapor"is"cooled"and"condensed"by"the"Condenser"(3"0HGA10"AC001/2)"against" vacuum"condensate"from"MPP3."

The" two" phase" mixture" from" the" Condenser" enters" the" Overhead" Accumulator" where" the" carbon"dioxide"and"condensed"water"are"separated."The"condensed"water"is"pumped"from"the" Overhead"Accumulator"by"the"Reflux"Pump"(3"0HGA30"AP001/2)."A"portion"of"the"condensate"is" returned"to"the"Stripper"as"reflux"and"the"remaining"liquid"from"the"Overhead"Accumulator"is"

sent"to"the"Absorber."The"carbon"dioxide"rich"vapor"is"sent"to"the"CO2"Product"Compressor"(3" 0HGB10"AN001)."

The" lean" solvent" leaving" the" Stripper" is" sent" to" a" Lean" Flash" Drum" where" it" is" flashed"at" near" atmospheric"pressure."The"resulting"flashed"vapor"is"returned"to"the"Stripper"via"the"Lean"Vapor" Compressor"(3"0HKH40"AN001)."The"lean"solvent"from"the"Lean"Flash"Drum"is"pumped"by"the" Lean"Solvent"Pump"(30HKG30"AP001/2)"to"the"Solvent"Cross"Exchanger."After"passing"through" the"Solvent"Cross"Exchanger,"the"lean"solvent"stream"is"routed"back"to"the"Absorber."A"portion" of" the" lean" solvent" stream" is" sent" to" the" Carbon" Bed" (3" 0HKF20" AT001).The" filtered" solvent" returns"to"the"main"lean"solvent"line"where"it"is"returned"back"to"the"Absorber."

4.1.4Solvent-reclaiming-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"45.""

A"slip"stream"of"hot"lean"solvent"from"the"bottom"of"the"Stripper"is"taken"out"through"a"semi:

continuous"reclaiming"operation."Also"a"20"wt%"NaOH"solution"stream"is"taken"to"the"reclaimer" system" package." The" recovered" solvent" is" sent" back" to" the" Lean" Flash" Drum." The" reclaimer" waste"is"routed"to"the"Reclaimer"Waste"Sump"and"periodically"shipped"off:site"for"disposal."

4.1.5Solvent-make$up-and-holding-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"45.""

The"make:up"solvent"is"stored"in"the"Solvent"Storage"Tank"(3"0HKJ20"BB001).Solvent"make:up" (normally"no"flow)"can"be"injected"into"the"lean"solvent"line"when"required."The"solvent"is"sent"

Maasvlakte"CCS"Project"C.V."

from" storage" to" the" lean" solvent" line" by" Solvent" Makeup"Pump" (3" 0HKJ40" AP001)" via" Solvent" Make:up"Pump"Suction"Heater"(3"0HKJ30AC001)."

A"Solvent"Holding"Tank"(3"0HKJ50"BB001)"is"required"to"store"the"solvent"inventory"in"the"event"

of"a"scheduled"maintenance"or"shutdown."The"solvent"can"be"transferred"to"the"holding"tank"via" the"Lean"Solvent"Pump"(to"the"Absorber)"and"Rich"Solvent"Pump"(to"the"holding"tank)."After"the" maintenance"or"shut"down"is"complete,"the"solvent"in"the"holding"tank"can"be"transferred"back" to"the"Absorber"using"the"Solvent"Transfer"Pump"(3"0HKJ60"AP001)."

4.1.6CO2-compression,-oxygen-removal,-and-dehydration-

The"Process"Flow"Diagram"of"this"section"can"be"found"in"Appendix"2"on"page"46.""

Following"recovery,"the"CO2"product"must"be"compressed"and"purified"to"meet"pipeline"water" and" oxygen" specifications." The" CO2" Product" Compressor" (3" 0HGB10AN001)" compresses" the" product" carbon" dioxide" to" 129" bar(a)." The" product" gas" is" cooled" after" each" stage" of" compression."Any"condensed"water"is"separated"from"the"gas"in"knockout"drums"for"each"of"the" first"five"stages"of"compression."

A" CATOX" Unit" (3" 0HGC10" BB001)" is" used" to" reduce" the" oxygen" concentration." The" required" hydrogen" gas" will" be" procured" and" stored" in" gas" cylinders." The" CATOX" Unit" is" a" reactor" containing"a"highly"reactive"catalyst"that"allows"the"safe"and"controlled"combustion"of"hydrogen" with"oxygen,"producing"water"which"is"knocked"out"after"cooling."

The"gas"leaving"the"CATOX"Unit"is"cooled"and"partially"condensed"in"the"CATOX"Aftercooler"(3" 0HGC20"AC001)."Condensed"water"is"then"removed"in"the"Water"KO"Drum"(3"0HGC30"BB001)."

Overhead" gas" from" the" Water" KO" Drum" is" sent" to" the" CO2" Dehydration" Package" (3" 0HGC40" AT001)"to"reduce"the"water"content"in"the"stream"to"below"the"required"dew"point."After"the" final"stage"of"compression,"the"product"carbon"dioxide"stream"is"cooled"to"60°C"and"routed"to"

the"battery"limit"at"129"bar(a)"for"pipeline"transportation."All"water"from"the"CO2"Dehydration" Package,"Water"KO"Drum"and"compression"interstage"KO"drums"is"combined"and"routed"back"to" the"Lean"Flash"Drum."

4.2Simplified-process-flow-diagrams-of-capture-and-compression-

In" Appendix" 2" you" will" find" the" simplified" process" flow" diagrams" of" capture" plant" and" compressor.!

4.3Overall-heat-and-material-balances-

In"tables"4.1"and"4.2"the"heat"and"mass"balances"can"be"found"on"a"general"level."The"stream"

numbers"correspond"to"the"streams"in"the"process"flow"diagrams"in"Appendix"2."

Within"the"FEED"study"itself"more"detailed"confidential"streams"have"also"been"considered"and" those" streams" served" as" input" for" the" figures" in" the" environmental" impact" assessment." However,"the"streams"in"tables"4.1"and"4.2"give"a"good"indication"of"the"amount"and"content"of" the"streams."

!