Technical Challenges for the ROAD Capture Project

Transcription

1 Technical Challenges for the ROAD Capture Project CATO CCS Symposium, Capture Workstream 20 th June 2014 Andy Read, Capture Director

2 Agenda Introduction to ROAD Capture Plant With thanks to CATO Remaining technical challenges A personal view Page 2

3 Agenda Introduction to ROAD Capture Plant With thanks to CATO Remaining technical challenges A personal view Future Priorities for Capture Technology As a project developer, what do I need the carbon capture community to develop for me? Page 3

4 Location of Capture Plant: Maasvlakte Power Plant 3 Coal-fired 1070 MWe 46-47% LHV efficiency Biomass co-firing in permit Commercial operation starts in 2014 Page 4

5 CO 2 Capture Unit Fluor postcombustion capture technology 250 MWe equivalent (23% of MPP3 flue gas) 90% capture CO 2 flow rate of 169 t/h Operational: 3 years after FID Page 5

6 Process overview Designed to deliver a robust EPC offer by end 2010 and give best value for money (by retaining competition) 11 firms were invited to bid, reduced to 6 then 2 and now 1. December 2009 Decision Project Strategy 11 requests for proposals January 2010 February 2010 Selection criteria Decision Preliminary study 1 Information Day (8 December 2009) Preliminary study 2. Preliminary study 6 March 2010 Notes: Red = Maasvlakte CCS Project C.V. actions Blue = Supplier(s) actions Green = Actions for both Selection criteria Decision Specifications for FEED study FEED study 1 FEED study 2 September 2010 Decision made Feb 2011 Negotiation Contract Decision Preferred EPC contractor selected Page 6

7 Why did we choose Fluor? Low capex (small vessels and simple design) Low risk: MEA is relatively environmentally benign (easier permitting) By far the most data is available for MEA (and also the cheapest to replace) The improved thermal performance promised by more modern solvents was not sufficient in the overall process designs to be a major differentiator That was 2010/2011. If we were to do comparative FEED studies in 2014, we don t know if we would get the same answer Maasvlakte CCS Project CV Page 7

8 Current Capture Plant Status FEED study completed (2010) Value engineering completed (2011) Cost reductions of some 4M identified Detailed engineering and procurement underway in 2011/ % model review completed in Q Seven contracts for long lead components signed in 2012 But all work was suspended in Q due to lack of funds No further work on ROAD Capture since Q2 2012, except Tie-ins to MPP3 R&D on emissions Remobilisation will follow an agreement on funding. Page 8

9 Support from CATO was considerable Pilot plant experience Emissions performance Aerosols, causes and effects Solvent management Cycle modelling Especially integration with the power plant Support for permits Risk assessment (hazards) Dispersion Degradation Page 9

10 Agenda Introduction to ROAD Capture Plant With thanks to CATO Remaining technical challenges A personal view Page 10

11 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control Page 11

12 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control Every pilot on coal [to my knowledge] has had solvent chemistry problems at some stage: Evidence of accelerating corrosion Rising metal content (especially iron) Rising ammonia emissions Rising amine degradation (after a time) But pilots were not designed for long term operation Topics for research: Understanding the long term solvent chemistry Reclaimer performance (and waste disposal) Corrosion prevention, for example via Commissioning approaches Selective removal of catalysts such as iron Corrosion inhibitors Alternative materials (maybe not for ROAD) Alternative solvents (not for ROAD) Page 12

13 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control Aerosols and consequent emissions are a clear concern based on the CATO pilot at MPP2 (although they have never occurred at a Fluor plant) WESP performance and location Alternative mist removal technologies Emission minimisation techniques Understanding and preventing aerosol formation Other emissions topics: Acid wash for ammonia Degradation products The fate of amines and degradation products in the environment ROAD specific: We mix our flue gas with untreated power plant flue gas ( rich in SO 2 ). How does this affect the fate of such products in the environment? Page 13

14 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control As ROAD, we want simple, robust on-line measurement devices. Permit is based on an FID, which is excellent, but not very specific. But simpler instrumentation with the power of an FTIR would be good. And also improved measurement of environmentally sensitive degradation products such as nitrosamines and nitramines. Page 14

15 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control Solvent monitoring is a particular concern: Lean / rich loading HSS Impurities such as iron Automated real-time monitoring is strongly preferable to sampling for lab analysis (especially for lean / rich loading) For safety and environmental and cost reasons Can we achieve and maintain closed energy and mass balances? There may be plenty of experience from other pilots here that ROAD hasn t yet gathered Page 15

16 Remaining technical challenges for ROAD (Things that keep me awake at night ) Long term solvent management Emissions control Emissions measurement Instrumentation Robust automated control There is a gulf between current capture plant automated control (at both reference plant and pilots), and what can be achieved with modern IT. Compare un-manned automated control available for bio-natural gas units ( control via a mobile phone app ) with all current pilots. Page 16

17 Some CCS economics The ROAD plant costs M capex (whole chain, but mostly capture) Assuming long term utilisation of about 75% and 25 year life, this capex equates to circa 40-50/t It uses 1 MWh electricity (as power and steam) for every 3t stored (of which almost half is power). At 60/MWh this equals 20/t Other operating costs are circa 10-20/t So total cost of circa 80/t In future 75% utilisation may be very optimistic for power plants due to large scale renewable generation Conclusion For CCS on electricity, capex is as big or bigger concern than opex: And will dominate in scenarios with a high percentage of renewable generation Page 17

18 Future R&D Priorities (a personal view) Reduced capital cost Reduced operating cost Known environmental impact Reduced environmental impact Easy to use (standard technology) Page 18