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

Maasvlakte&CCS&Project&C.V.&

&

Table&4.4:&Impact&of&the&capture&plant&on&the&power&plant&process.&Efficiency&in&(LHV)&&

&

&

4.5Block&Flow&diagram&

On&the&next&page&you&can&find&the&block&flow&diagram&of&the&capture&and&compression&process& (figure&4.1).&

&

Maasvlakte&CCS&Project&C.V.&

4.6Integration-with-base-power-plant-

The&design&of&the&integration&is&done&by&E.ON&New&Build&&&Technology&BV.&The&coalHfired&unit& MPP3&is&already&under&construction&for&a&couple&of&years&and&therefore&the&integration&of&the& capture& plant& is& in& fact& a& retrofit& instead& of& a& completely& new& design.& All& major& components& (boiler,&turbine,&flue&gas&cleaning,&stack&etc.)&have&already&been&ordered&and&designed&prior&to& the& development& of& the& capture& plant.& This& means& that& in& this& demonstration& phase& some& solutions& have& been& chosen& that& fitted& well& in& this& situation,& but& might& not& be& the& solution& selected&when&capture&and&power&plant&are&designed&at&the&same&time.&&&

4.6.1Carbon-capture-plant-–-MPP3-interface-overview-

All& figures& and& data& in& this& report& are& based& on& full& load& operation& under& typical& operating& conditions.&Values&will&differ&for&different&load&factors&and&operating&conditions.&

4.6.2Flue-gas-

The& capture& plant& was& designed& for& an& equivalent& electrical& output& of& 250& MW& and& will& therefore&only&need&to&treat&a&slip&stream&of&the&flue&gas&produced&by&Maasvlakte&Power&Plant&3& (MPP3).&In&design&conditions,&the&capture&plant&needs&to&treat&23.4&%&of&the&flue&gas&from&the& FGD&of&MPP3.&The&flue&gas&slip&stream&has&a&volume&flow&of&698.000&Nm³/hr&at&48°C,&which&was& considered&as&the&maximum&volume&flow&to&the&capture&plant.&

A&flue&gas&slip&stream&will&be&extracted&from&MPP3&and&routed&to&the&capture&plant.&The&flue&gas&

will&be&extracted&after&the&Flue&Gas&Desulphurisation&(FGD)&unit&of&MPP3.&

The&discharge&of&the&treated&flue&gas,&which&has&a&volume&flow&of&566.000&Nm³/hr&at&35°C&will&

be&routed&back&to&the&wet&stack&of&MPP3.&

4.6.3Electric-power-

The& approx.& 20H30& MW& electrical& power& will& be& provided& via& a& 10HkVHswitchgear& that& will& be& installed& at& the& control&building&of&the& MPP3&power&plant& and& which& is& linked& to& a& 150/10&kV& transformer&that&is&connected&to&the&external&150&kV&grid.&

Since&the&supply&to&MPP3&from&the&external&150&kV&grid&is&required&only&in&emergency&cases&(e.g.& operating& failures& of& auxiliary& power& transformers),& the& capture& plant& can& be& supplied& with& electrical&energy&via&the&external&grid&transformer.&

In&case&of&the&above&mentioned&emergency&event,&MPP3&will&be&supplied&from&the&external&grid.&

The&10&kV&supply&to&the&CCS&system&would&be&dropped&automatically&in&case&of&this&event.&The& CCS&system&would&then&not&be&available.&A&reconnection&of&the&electrical&power&supply&to&the& CCS&system&would&be&done&manually.&

The&current&CCS&system&design&intends&to&supply&the&CCSHsystem&with&two&10kVHparts&with&nine&

or&eight&switchboards&each.&

4.6.4Cooling-water-

Normally&the&three&sea&water&cooling&pumps&of&the&main&cooling&system&of&MPP3&have&enough& capacity&to&provide&cooling&for&MPP3&and&the&capture&plant.&When&one&pump&is&not&available,& the&capture&plant&may&have&to&be&reduced&in&load&or&shut&down.&&

To&supply&12290&m³/h&cooling&(sea)water&to&the&capture&plant,&&it&is&foreseen&to&connect&suction& lines& to& each& of& the& two& manholes& (ID& 800mm)& of& an& inspection& well& in& the& concrete& cooling& water&channel&between&the&main&cooling&water&pumps&&and&the&machine&house&of&MPP3.&&

The& two& manhole& covers& will& be& replaced& with& (flanged& GRP)& DN800& pipe& spools& running& to& a& suctionheader,&which&feeds&the&capture&plant&cooling&water&booster&pumps.&The&DN800&spool& pieces&will&be&designed&in&such&a&way&that&they&are&removable,&which&will&allow&access&to&the& manholes&when&this&is&needed.&

Maasvlakte&CCS&Project&C.V.&

The& concrete& superstructure& around& the& manholes& will& also& be& modified,& allowing& the& suction& header&to&penetrate&the&superstructure&and&also&ensuring&sufficient&personnel&access.&

The&above&mentioned&modifications&to&the&existing&MPP3&cooling&water&channel&manholes&will& be&made&during&the&operational&phase&of&MPP3.&The&concrete&superstructure&can&be&modified& without&operational&consequences.&The&piping&from&the&manholes&to&the&capture&plant&can&also& be&installed&while&MPP3&is&in&operation.&

The&cooling&water&discharged&from&the&capture&plant&will&be&routed&to&the&outlet&pond&through&

an&existing&cooling&water&channel&running&adjacent&to&the&capture&plant.&&

4.6.5Steam-and-condensate-

When& MPP3& is& operating& in& full& load,& the& steam& (<100& kg/s& at& 2H4& bar)& that& is& used& in& the& desorber&(stripper)&of&the&capture&plant&will&be&extracted&from&the&steam&turbine&downstream&of& the&medium&pressure&turbine.&In&part&load&of&MPP3&this&pressure&is&not&high&enough&and&another& (higher&pressure)&extraction&point&will&have&to&provide&the&steam.&&

Design&of&this&extraction&system&is&still&pending&as&optimization&is&of&high&importance&because&of&

the&high&operational&costs&involved.&What&are&the&scenarios&–&advantages&and&disadvantages?&&

Three&scenarios&are&evaluated&to&have&increased&steam&pressure&in&part&load:&

1.Modification& of& the& crossover& pipe& MP& to& LP& turbine& and& installing& valves& to& keep& enough&pressure&during&part&load.&(High&investments;&operational&risks,&long&outage)&

2.Extraction&from&a&higher&pressure&source&(low&part&load&efficiency).&

3.Installing& a& steam& jet& booster& to& increase& the& pressure& extracted& from& the& main& extraction&point&(more&complex&and&extra&investments).&&

The&approx.&1200&mm&steam&line&will&be&routed&on&a&450m&long&dedicated&pipe&bridge&together&

with&other&piping&needed&for&the&utilities&of&the&capture&plant.&&

The&condensate&from&the&steam&will&be&routed&back&to&the&condensate&system&of&MPP3.&

4.6.6Condensate-for-cooling-

The&design&basis&for&this&project&identifies&an&opportunity&for&heat&integration&between&MPP3& and&the&capture&plant&via&preHheating&steam&condensate&within&the&capture&plant.&

This&condensate&will&be&supplied&at&19&bar(a)&and&26°C;&it&will&be&returned&at&16H18&bar(a)&and&

70H100°C.&

The&condenser&that&cools&the&stripper&overhead&gas&is&an&ideal&heat&source&for&preheating&this&

condensate.&The&hotHside&enters&the&condenser&at&89°C&and&is&cooled&to&40°C.&This&means&that&

the&full&heat&load&(28,8&MW)&of&the&condenser&can&be&used&for&condensate&preHheating.&The&preH heated&condensate&is&returned&to&the&MPP3&at&18&bar(a).&

4.6.7Flue-gas-condensate-and-deep-FGD-waste-water-

The&waste&water&that&is&produced&by&the&preHscrubber&section&of&the&capture&plant&is&divided&in&

two&split&streams.&The&preHscrubber&combines&a&cooling&section,&the&direct&contact&cooler&(DCC)& and&a&desulphurization&unit,&the&deep&flue&gas&desulphurization&unit&(deep&FGD).&Both&sections& produce&waste&water,&whereas&the&split&streams&differ&significantly&in&quantity&and&quality.&

The&DCC&excess&water&stream&amounts&to&44&t/hr&and&consists&of&flue&gas&condensate.&The&split&

stream&out&of&the&deep&FGD&is&smaller&with&only&0,3&t/hr.&

The&DCC&excess&water&stream&can&be&mixed&with&process&water&for&feeding&the&FGD&absorber&of&

MPP3,&thereby&reducing&the&intake&of&fresh&water&from&a&nearby&lake&by&more&than&a&third.&

Maasvlakte&CCS&Project&C.V.&

4.6.8Other-interfaces-

Several& other& interfaces& are& identified& and& will& be& engineered& to& ensure& a& safe& and& efficient& operation.&Those&interfaces&include:&

6.Control&connections&

7.Telecom&connections&

8.Alarm&connections&

9.Fire&water&

10.Sewage&water&

11.Potable&water&

4.7Sized-equipment-list-

In& Appendix& 3& the& complete& equipment& list& can& be& found.& It& contains& the& specification& of& blowers,&compressors,&exchangers,&filters,&vessels,&pumps,&sumps,&tanks&and&specialties.&

&

•Basis-for-Material-Selection-

Materials& of& construction& are& selected& and& the& corrosion& allowances& are& determined& on& the& basis& of& anticipated& corrosion& or& material& degradation& under& the& most& severe& combination& of& process&variables&resulting&in&sustained&maximum&normal&operating&condition.&&

The&risk&of&damage&due&to&a&short&term&condition&such&as&an&alternate&operation,&startup,&shut&

down,&upset&and&emergency&conditions&is&evaluated&as&follows:&

It& is& first& determined& if& the& short& term& condition& will& introduce& or& concentrate& a& corrodent& or& cause& a& resident& corrodent& to& become& active& as& a& result& of& causing& an& aqueous& phase& to& be& present&or&crossing&a&temperature&or&partial&pressure&threshold.&

The&estimated&duration&of&upset&is&used&to&estimate&a&prorated&corrosion&rate.&The&prorated&rate&

is&then&used&to&evaluate&the&necessity&for&extra&corrosion&allowance&and&perhaps&an&upgrade&in&

materials&selection.&

If&the&corrodent&of&concern&is&a&crackHinducing&agent,&prorating&is&not&normally&permitted.&The& normal& response& to& the& process& of& even& a& transient& active& crackHinducing& agent& is& a& materials& upgrade&or&the&adoption&of&a&preventive&measure&such&as&cladding.&

Materials&specified&are&the&minimum&requirement.&Higher&alloys&may&be&applied&due&to&practical& considerations&(i.e.,&availability,&ease&of&fabrication,&etc.).&

&

•Amine-Corrosion-and-Stress-Corrosion-Cracking--

Corrosion& of& carbon& steel& (CS)& components& in& amine& services& is& not& caused& by& amines& themselves&but&by&dissolved&acid&gases,&such&as&CO2,&or&by&amine&degradation&products,&such&as& heat& stable& salts.& Variables& affecting& the& corrosion& rates& are& the& type& of& acid& gas,& the& type& of& amine,& solvent& concentration,& gas& loading,& temperature,& solution& purity,& velocity,& use& of& inhibitors,&design,&and&metallurgy.&

The&use&of&stainless&steel&alloys&will&provide&excellent&resistance&to&the&nonHinhibited&lean&and& rich&amine&streams.&These&alloys&will&resist&MEA&corrosion&at&all&temperatures&being&specified&in& the&Econamine&FG&PlusSM&process.&&

Thermal&stress&relief&(e.g.,&Post&Weld&Heat&Treatment&or&PWHT)&is&considered&the&most&effective&

means&of&preventing&amine&SCC&on&the&unclad&CS.&All&welds&and&bends&must&be&stress&relieved& including& external& attachment& welds& at& components& with& wall& thicknesses& less& than& about& 25& mm,&as&the&residual&stresses&from&these&welds&can&extend&through&the&wall&to&the&inner&surface& and&initiate&cracking&from&the&inside&diameter&

Maasvlakte&CCS&Project&C.V.&

(ID).& In& the& past,& some& refiners& and& gas& plant& operators& stress& relieved& only& above& certain& operating&temperatures,&but&due&to&various&failures,&most&of&the&industry&now&stress&relieves&in& all&amine&services&except&ambient&temperature&storage&tanks.&This&represents&other&savings&with& the&use&of&stainless&steel,&as&PWHT&is&typically&not&needed.&

&

•Wet-CO2-Corrosion-

Wet&CO2&forms&carbonic&acid&which&is&corrosive&to&carbon&and&low&alloy&steels.&In&this&unit,&this& corrosion&mechanism&is&a&concern&in&the&“wet”&areas&with&CO2&and&no&amine.&For&this&plant,&all& areas&with&CO2&corrosion&are&recommended&to&be&304L&SS&stainless&steel&(or&better&based&on&the& chloride&SCC).&On&some&gas&lines,&CS&can&be&considered&if&steps&to&prevent&condensation&are&also& implemented.&

4.8Simplified-plot-plan-

MPP3& is& located& in& the& northern& part& of& the& Maasvlakte& area.& The& wellHpopulated& residential& areas&of&Hoek&van&Holland&and&Oostvoorne&are&located&at&a&distance&of&approximately&7&km&from& the&MPP3&site.&The&characteristics&of&the&Maasvlakte&area&are:&

•Container&terminals&

•Ore&and&coal&terminals&(EMO)&

•Chemical&industry&(Lyondell)&

The&capture&installation&will&be&built&on&the&plot&space&next&to&the&stack&of&MPP3.&Because&the& MPP3& installation& is& designed& and& already& under& construction,& the& plot& space& has& some& challenges&for&the&capture&installation&compared&to&a&greenfield&situation.&On&this&plot&there&is& an&area&without&height&limitation,&an&area&with&height&limitation&due&to&coal&transport&conveyor& belts& and& an& area& where& underground& cooling& water& piping& is& located.& Furthermore,& 10.5&kV& cables&are&routed&on&top&of&the&cooling&water&duct&which&is&crossing&the&site.&Pipe&racks&on&the& Maasvlakte&site&have&a&passage&height&of&5&m&and&at&some&areas&of&8&m.&&

The&supplier&managed&to&design&the&capture&installation&to&fit&all&the&restrictions.&In&Figure&4.2&a&

picture&is&placed&from&the&simplified&plot&plan.&The&enlarged&version&is&found&in&Appendix&4.&The& total& area& available& for& this& demonstration& is& circa& 1.2& Ha.& This& area& is& separated& by& the& coal& conveyor&belt&of&MPP3.&

&

Maasvlakte&CCS&Project&C.V.&

5.Health,-Safety-and-Environment-issues-

5.1Environmental-emissions-

This& section& describes& the& environmental& emissions& associated& with& the& ROAD& project.& The& information&in&this&chapter&is&based&on&the&environmental&impact&assessment.&The&actuals&might& differ&in&the&future,&but&this&is&the&current&assumption&for&the&CCS&installation&(June&2011).&In&the& Environmental& Impact& Assessment& (EIA& note:& information& is& in& Dutch),& more& detailed& information& on& the& emissions& and& noise& can& be& found.& In& Appendix& 5& the& MSDS& of& MEA& and& NaOH&can&be&found.&

5.1.1Emissions-to-air-

In&the&capture&installation&circa&23%&(volume)&of&the&flue&gases&from&MPP3&will&be&treated.&The& treated&flue&gas&will&be&sent&back&to&the&stack&of&MPP3,&mixed&with&the&remainder&of&the&flue& gases&of&MPP3&and&emitted&to&air&by&the&existing&stack&of&MPP3.& Three&relevant&operating&modes&are&described&to&be&able&to&calculate&the&environmental&impact:&

•Operating&mode&1.&MPP3&operational&without&the&CCS&installation.&

•Operating&mode&2.&MPP3&full&load,&CCS&fully&operational,&circa&23%&of&flue&gas&treated&

•Operating&mode&3.&MPP3&part&load,&all&flue&gas&treated&in&CCS&installation.&Concentration&

will&change,&but&environmental&load&stays&equal.&

In&Table&5.1&the&assumptions&for&the&composition&of&the&flue&gas&are&stated.&

&

&

Table&5.1:&Assumptions&for&composition&of&flue&gas&

Maasvlakte&CCS&Project&C.V.&

Tabel&5.2:&Emissions&from&the&installation&(MPP3&and&capture&plant)&&

1)&NO2&based&on&5%&of&NOx&

&

In&Table&5.2&the&emissions&of&Operating&mode&2&(full&load)&and&3&(part&load)&are&indicated.&The& emissions& at& part& load& are& equal& to& the& emissions& at& the& outlet& of& the& capture& plant.& The& emissions&at&full&load&are&representative&for&the&combined&stream&of&flue&gases&where&a&part&is& treated&in&the&capture&plant.&The&emissions&are&based&on&a&yearly&average&value.&

5.1.2Water-

• Process-water-

During&capture&of&CO2&process&water&is&released&in&a&number&of&places.&&

In&the&first&place,&at&normal&operation,&circa&40H50&m3&per&hour&of&condensate&water&is&released& from&the&flue&gas&pretreatment.&This&process&water&occurs&by&cooling&of&the&saturated&flue&gas.& This&water&can&be&used&in&the&flue&gas&desulphurisation.&

The&flue&gases&are&further&desulphurized&by&the&use&of&a&sodium&hydroxide&solution.&The&sulphur& compounds&react&with&this&liquid&and&are&removed&with&a&surplus&of&water.&Per&hour&circa&0.3&m3& of&this&kind&of&process&water&is&produced&containing&sulphuric&substances.&

•Cooling-water-

In&the&capture&process&cooling&water&is&used&for&several&cooling&steps.&The&incoming&flue&gas&is&

cooled.&In&the&absorber&the&washing&water&is&cooled,&and&the&pumps,&fans&and&compressor&needs&

to&be&cooled&as&well.&

The&cooling&water&intake&of&MPP3&conforms&to&the&current&permit&of&120000&m3/hour&of&which& the&capture&installation&needs&a&maximum&of&15000&m3/hour.&The&cooling&water&is&sea&water.&By& raising&the&temperature&difference&between&cooling&water&inlet&and&outlet,&the&mass&flow&of&the& cooling&water&remains&constant.&&