Technical Proposal Write Up Rev 1 200910
Technical Proposal Write Up Rev 1 200910
Technical Proposal Write Up Rev 1 200910
September 2010
428_8302_B838_DR_80000_4_6300_A
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CONTENTS
1. Introduction.............................................................................................3
1. Introduction
Post Combustion CO2 Capture (PCCC) is a process which uses liquid chemical
absorbents to remove CO 2 from flue gas. The process is based on a well established
chemical processing technique used in the petrochemical industry to clean sour fuel gas
and has been adapted to meet the environmental challenges of CO 2 emission
abatement in the fossil fuel combustion power sector.
It is understood that SSE has completed a Preliminary Site Feasibility Study for the
provision of a PCCC plant at Peterhead Power Station and is now seeking proposals for
a Feasibility Study. Doosan Power Systems is pleased to provide this brief technical
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write up as part of its submission. The aim of this submission is to provide SSE with a
basic description of the likely PCCC plant solution and also to offer a simple explanation
of what Doosan Power Systems propose to provide in response to SSE’s requested
deliverables.
temperature to the optimal temperature before it enters the CO 2 absorber column. The
DCC consists of a packed bed column in which cold water is circulated flowing from top
to bottom with the flue gases flowing in a counter current arrangement from bottom to
top to maximise heat transfer. Any water make–up (i.e. initial fill) to this circuit will be
provided from the process water supply though it should be noted that this will generally
only be needed for initial filling as the DCC unit will generate an excess of water due to
the condensation formed from the reduction in flue gas temperature. A proportion of this
water will be utilised by the downstream capture process.
The CO2 absorber column consists of a multi-stage packed column where CO 2-lean
solvent is pumped into the top of a packed column with CO 2-laden flue gas flowing
counter-current from the bottom. The absorber unit is designed so that typically 80%-
90% of the flue gas CO2 is absorbed by the solvent. The resultant CO 2-rich solvent is
collected at the bottom of the absorber from where it is pumped through a filter system
prior to being heated within the lean/rich heat exchanger and passed onwards to the
stripper column.
Up to two stages of water wash sections may be located above the absorption stages in
the absorption column. The first stage is used to recover evaporated/entrained solvent
and derivatives and the second stage is needed to control ammonia (NH 3) emission
levels before the remaining flue gas (termed ‘offgas’) can be vented to atmosphere.
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In this heat exchanger hot CO 2-lean solvent from the CO2 Stripper is utilised to partially
heat the CO2-rich solvent from the absorber before it enters the CO 2 Stripper Column.
This level of heating initiates the stripping process prior to admission to the stripper
column as some of the CO2 is liberated as a gas towards the hot end of the exchanger.
Additionally this heat recovery pre-cools the lean solvent to as close to a suitable
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temperature for Absorber Column injection as possible and therefore minimises the
cooling duty needed in the lean solvent cooler.
CO2 Stripper
CO2-rich solvent is passed to the top sections of the stripper column where it falls
through packing which ensures sufficient contact is achieved with the rising vapours
(steam and CO2) generated in the reboiler. This hot vapour stream strips CO 2 gas out of
the rich solvent which consequently yields ‘lean solvent’. The rising vapours are
enriched with CO2 as they pass upwards through the packing and emerge at the top of
the stripper column where they are passed to a water-cooled condenser which removes
the bulk of any entrained solvent/water vapour for return to the solvent circulation system
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via the reflux liquid stream. The resultant cool water-saturated CO 2 stream, or ‘product’
stream, is passed to the CO 2 compression and dehydration system for further
processing.
From the base of the stripper column, the regenerated CO 2-lean solvent is passed back
through the Lean/Rich Heat Exchanger before being pumped through the Lean Solvent
Cooler (for temperature control) before being passed to the top of the absorption
sections of the Absorber Column to complete the circulation loop.
Reboiler
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The reboiler is used to generate a hot vapour stream from the CO 2-lean solvent that is
collected at the bottom of the stripper column. The solvent passes through the reboiler
via natural circulation (i.e. there is no pumping required). Heating is provided via a plate
type heat exchanger using attemperated LP steam from the appropriate superheated
steam supply. The condensate generated from this indirect heating system is returned
to for recovery into the appropriate condensate system. Appropriate on-line analysis of
the condensate will be undertaken to guard against the risk of condensate contamination
by solvent components.
Solvent Reclaimer
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A vacuum solvent reclaimer is proposed to recover useful solvent from the heat stable
salts that are formed by reaction with flue gas acid gases and piping system corrosion.
The process uses a combination of direct heating along with the addition of certain
chemicals to stabilise the salt components and maximise recovery of useful solvent
components. Vacuum operation is required for select solvents to achieve high recovery
rates. Cooling water is required for condensation of low pressure evaporated solvent
from the vacuum stages to facilitate the return of the liquid solvent to the system by
pumping.
sunsequent FEED study and appropriate technology selection will be based on the
overall through life costs of the competing systems.
In order to meet the required export characteristics for the CO 2, a compression and
dehydration process is required. Multi-stage geared compression system will typically be
used to achieve the desired downstream CO 2 pressure target. Although the
compression process will lower the moisture content (extracted through the use of inter-
stage liquid knock-out drums), the final composition of the CO 2 will be met by application
of a dehydration process to one of the interstage streams in the compression train.
Doosan Power Systems will provisionally consider the use of a triethyleneglycol (TEG)
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system for this purpose, after which the gas will be returned to the compressor system
for final compression to supercritical conditions. If higher quality CO 2 product is required
a Molecular Sieve may be required.
CO2 is generally denser than air which can restrict dissipation; the temperature of the
gas stream following condensation is around 40°C which though hotter than the
surrounding air is not sufficiently hot to deliver the required buoyancy to ensure good
dispersal. It would therefore intended that leakage detection be installed around
appropriate parts of the plant to provide early warning to personnel of any leakage.
Equally, any discharge from a pressurised CO 2 source (such as downstream
compression plant) will also result in a ‘denser than air’ gas volume that will collect in low
points of the system. Drainage sumps and trenches are particularly at risk of this hazard
and so CO2 detection would also be installed where appropriate in these locations.
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The substances used within the carbon capture process are not directly applicable to the
COMAH regulations. Risk phrases applicable to the solvents proposed are: R20/21/22
harmful if swallowed/inhaled on by skin contact, R34 causes burns, R35 causes severe
burns (caustic only), R36 irritant to eyes, R41 risk of serious damage to the eyes and
R48/22 danger of serious damage to health by prolonged exposure if swallowed.
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three Gas Turbines operate with Siemens Heat Recovery Steam Generators
oriented horizontally and discharge into the common exhaust stack (location 6).
There is an additional 660 MW Steam turbine. However, with limitations imposed
by transmission constraints this unit is not utilised for power generation.
SSE preference would be to utilise the full exhaust gases from Gas Turbine and
Heat Recovery Steam generator shown in location 1 for PCCC as a base load.
The approximate size of the capture plant would be of the order of 3,000 tonnes
per day.
The preferred location for the PCCC plant would be in place of the existing fuel
oil storage tanks, northwest of the Steam Turbine Building (location 5). The
existing fuel oil tanks were a part of the pre-existing set-up. It is understood that
they do not serve any useful purpose at present and that these tanks would be
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demolished. The dimensions of the area thus made available will be of the order
of 320 m x 110 m.
The proposed PCCC area is free from overhead high voltage lines. Access to this
location is suitable for heavy traffic- either through A90 from the Peterhead
harbour from the North or, through the construction of an intermediate jetty near
CW outwash (location 4). Considerable lay-down area is available and
unimpeded movement of heavy duty gantry crane required for construction would
be possible. Refer to location 2.
SSE confirmed that the operation of the unit for integrated carbon capture would
essentially be base load operation in combined cycle mode. The requirement of
transient operations like ramp-up for frequency support would be met by the
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other gas turbines and would not have to be considered for the design of the
PCCC plant.
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2
1 56 3
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Figure 1: Peterhead CCGT with proposed Carbon Capture Plant
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In view of the redundant capacity, SSE proposes to demolish the enclosed areas in
Figure 2 for the routing of the flue gas between the exhaust stack and the carbon
capture plant (location 2 in Figure 1); which is shown in Figure 2 as a yellow corridor,
approximately 460 m in length.
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The cooling water line is routed as buried piping to the north of the steam turbine
building (location 5 in Figure 1) to the condensers. From the condensers, the cooling
water lines are routed to the outwash channel (location 4 in Figure 1). It is proposed that
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the cooling water intake to the carbon capture plant be tapped through a new supply and
return line to minimise disruption and civil costs. This would be approximately 140 m in
length.
Steam Turbine
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The normal flow to both LP turbines is expected to be of the order of 375 kg/s, which is
responsible for around 220 MW power output of the 660 MW total. For each LP turbine,
this translates into approximately 187.5 kg/s, which is responsible for generating
approximately 110 MW of power.
For the steam turbine, the diversion of steam away from an LP turbine for use in the
PCCC plant leads to a small proportion of power loss. It is understood that is currently
considering a reduction in power generating capacity from the steam turbine and thus
utilising a proportion of this steam for the PCCC plant may be an attractive option for
SSE.
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The engineering requirement of partial loading of the steam turbine can be easily
achieved by installing appropriate pressure regulating equipment in the cross-over line
from the IP Turbine to one or both of the LP Turbines and extracting steam upstream for
the PCCC plant. This regulates the pressure as per Traupel’s Cone Rule illustrated
below in Figure 3 and does not allow the increase of differential pressure across the last
stages of IP Turbine blades which are normally designed for stress’s approaching the
maximum utilisation factor. The operation would need to be confirmed by the steam
turbine OEM.
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Figure 4: Proposed location of steam extraction for PCCC from Crossover pipe
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The Heat Recovery Steam Generator is Siemens design unit and consists of 3 drums
(high pressure, intermediate pressure and low pressure) heated by the exhaust flue gas
from the gas turbines in a horizontal configuration, as per Figure 6
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The Heat Recovery Steam Generator is not equipped with an external deaerator and
does not incorporate supplementary firing (the provision for which exists but has not
been implemented) as per the empty space seen in Figure 7. The available design
margins might be considered as a part of the techno-economic optimisation.
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The operational viability of the preferred mode of operation would have to be guaranteed
by the Heat Recovery Steam Generator OEM.
Doosan would request SSE to furnish the following details prior to exploring further
design possibilities with the HRSG:
All Heat Balances and Pressure vs. Steam Maps of the GT + HRSG similar to Figure 11.
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This is necessary to explore the complete operational availability of steam for the
regeneration of the rich solvent of the carbon capture plant in the re-boiler section of the
stripping process.
For generating 3480 tons per day of CO2, which translates to (3480/24 =) 145 tons per
hour or 40.28 kg/s, with a preliminary steam requirement of 1.2 kg per kg CO2, this
means a steam requirement of 40.28 x 1.2 = 48.3 kg/s.
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as per “Carbon capture and its storage: an integrated assessment” by Simon Shackley
and Clair Gough; with further inputs from SSE.
1 GT (open cycle) + 2 GT + 1 ST without carbon capture (present situation)
1 GT (open cycle) + 2 GT + 1 ST (partially loaded) with carbon capture
2 GT (open cycle) + 1 GT + 1 ST (partially loaded) with carbon capture
The economics of carbon capture would have to consider the choice of sequestration or
enhanced oil recovery (EOR) as per the following extract.
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Doosan Power Systems can assist SSE in exploring the various economic alternatives
for the most efficient running of various combinations of equipment for maximum
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operating flexibility. This has not been specifically requested as part of the Feasibility
Study. However, Doosan Power Systems would welcome the opportunity to discuss
closer collaboration with SSE at an appropriate stage in its project/study development.
Doosan Power System will provide SSE with a description of the Carbon Capture
process and the main plant components including where appropriate ducting, fans,
vessels, tanks, pumps, exchangers, electrical and control systems etc. anticipated for
the provision of an operational PCCC plant.
Doosan Power Systems will identify the anticipate operating envelope of the PCCC
plant. This will include expected turndown range and main expectations for plant start up
and shutdown.
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Doosan Power Systems will provide SSE with an indication of the estimated PCCC plant
efficiency in terms of CO2 capture, various anticipated emissions and a schedule of
expected performance parameters that might form the basis for development of
performance guarantees.
c) Preliminary Process Flow Diagrams, Heat and Mass Balances (full and minimum
load).
Doosan Power Systems will provide preliminary PFD and Heat and Mass Balances at full
and minimum load (2 load cases).
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Doosan Power Systems will identify all anticipated chemicals required for the normal
operation of the PCC process including a estimation of consumption and a description of
recycling, reclamation or disposal.
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f) Short specifications of significant new equipment items and modifications to cover key
process equipment.
Doosan Power Systems will provide basic specification (e.g. via technical datasheet) for
significant proposed plant components.
Doosan Power Systems will work with SSE to identify and agree the full range of tie in
points between the PCC plant and the existing station.
Doosan Power Systems will identify the expected pressure, temperature and
composition of the CO2 at the outlet of the compressor. Doosan would however seek
guidance on the requirements as these parameters might typically be specified to meet
the needs of the CO2 sink.
Doosan Power Systems would endeavour to identify the key impacts of the PCC on the
existing power plant. This would include the expected overall energy penalty along with
major disruption and plant interfaces.
Doosan would intend to undertake a preliminary internal HAZID study. Doosan would
anticipate involvement of a limited number of key individuals within this study, including
an appropriate representative(s) from SSE.
Doosan Power Systems will prepare a preliminary Control Philosophy for inclusion within
the feasibility study.
An assessment of appropriate buildings and associated civil and structural works will be
made during the Feasibility Study. The preliminary design will identify the expected
extent of buildings such as compressor house, control room etc
Doosan Power Systems will prepare an outline project schedule identifying the
anticipated top level schedule for further study and EPC.
Doosan Power Systems, working with SSE to ensure that any proposed suppliers are
acceptable to SSE, will prepare a list of vendors covering the main equipment items.
maximum operating flexibility. Doosan Power Systems would welcome the opportunity to
discuss this further with SSE.
The time available for the completion of the Feasibility Study will only permit limited
engagement with the supply chain. Doosan Power Systems will prepare an appropriate
CAPEX estimate based largely upon its internal cost database with direct supply chain
interface where necessary.
Doosan Power Systems will identify the expected energy consumption of the PCCC
plant and relate this to the operational output of the power plant to provide an
assessment of the anticipated efficiency penalty. This will require the assistance of SSE
through provision of appropriate information.
(1) Operating costs will be split into fixed operating costs and variable operating costs.
Where costs are in the form of utility consumption the Consultant will provide the
consumption rate in SI units. The Employer will convert utility consumptions to monetary
values for their own purposes.
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(2) Operating costs will NOT include fuel costs or efficiency penalties.
Doosan will identify strategic spares requirements for main equipment items.
In undertaking the Feasibility Study Doosan Power Systems would endeavour to identify
and recommend supplementary studies deemed necessary. It might be that any such
studies could be incorporated within subsequent stages of the design development (e.g.
Pre-FEED or FEED stage), either undertaken directly by SSE or by Doosan Power
Systems.
Doosan will commence a project risk register. It is anticipated that this would form a 'live'
document to be further developed during subsequent studies.
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c) Consultant’s Scope and detailed (cost, time and resource schedules) quote for
professional services to complete a Pre-FEED Study that will deliver a report as to how
the proposed technology could be implemented at Peterhead Power Station
Doosan would prepare its proposal for a next stage Pre-FEED Study.
Doosan Power Systems has made due allowance in its proposal to cover these other
requirements.
SSE has identified a number of items of site specific information that it intends to provide
to facilitate the Feasibility Study. Doosan Power Systems welcomes the provision of any
relevant information pertaining to the proposed PCCC plant and its integration within the
Peterhead Power Station. Doosan Power Systems would seek to work closely with SSE
to obtain or establish all information necessary to ensure a robust Feasibility Study. This
may include information beyond that which SSE has currently identified.
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