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Webinar: From compressor to reservoir – Flow assurance and control philosophy for CCS CO2 operation
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Webinar: From compressor to reservoir – Flow assurance and control philosophy for CCS CO2 operation

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The Rotterdam Capture and Storage Demonstration Project (ROAD) has completed a report for the Global CCS Institute to investigate issues surrounding CCS operation under different operating conditions, ...

The Rotterdam Capture and Storage Demonstration Project (ROAD) has completed a report for the Global CCS Institute to investigate issues surrounding CCS operation under different operating conditions, including start-up, shutdown and emergencies. Various strategies have been developed to provide robust, safe, and efficient operating solutions at different focal points along the CO2 chain, including the compression unit, the transport, and the injection platform.

At this webinar, Jan Uilenreef, Project Manager Transport & Storage, ROAD | Maasvlakte CCS Project C.V., presetned the findings about the CCS CO2 chain operation based on the practice of ROAD, as well as some recommendations for future CCS projects operation.

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  • I think that you can say it, but please do not put it into the slides.   The idea that the plant will come off at high electricity price is politically sensitive.  The intent is only to come off when there is a real shortage of capacity on the system, so for periods of only a few hours during cold winter mornings or evenings.  Thus we help make the electricity system more secure.  We do not want to give the impression that the CCS plant won’t run much.   However, given the possibility of capacity shortages, we need to be able to turn the CCS plant on and off rapidly, and be able to stop and start at will. We are not designing for many starts and stops as a base assumption; we are designing to be able to start and stop whenever we need to.  Whether we actually do lots of starts will depend on the market and the funding.

Webinar: From compressor to reservoir – Flow assurance and control philosophy for CCS CO2 operation Webinar: From compressor to reservoir – Flow assurance and control philosophy for CCS CO2 operation Presentation Transcript

  • From compressor to reservoir – Flow assurance and control philosophy for CCS CO2 operation Webinar – 15 April 2014, 1700 AEDT
  • Jan Uilenreef Jan Uilenreef is Project Manager with an excellent understanding of and long experience with process engineering of industrial plants, and project management of a variety of natural gas and CO2 pipelines and CO2 installations. Since November 2010 he is responsible for the design and engineering of the 16” CO2 pipeline that connects the Road Capture Plant with the TAQA platform on top of the P18-A exhausted gas field. He was previously responsible for several new build projects, most notably the design, engineering and construction of the OCAP CO2 pipeline in the Netherlands and the design engineering, construction and operation of the WarmCO2 facilities to deliver CO2 and waste heat to the greenhouse area in Terneuzen in the Netherlands. Jan has over 40 years of experience in the industry, including design and project development.
  • Dr Andy Read Andy Read is a Project Manager with an excellent understanding of power plant technology and the electricity markets with the associated commercial constraints. For the last five years, he has focused on CCS project development leading projects at Killingholme and Kingsnorth in the UK, and now as Capture Director for the E.ON / GDF SUEZ joint venture at Maasvlakte, Netherlands (ROAD Project). He has previously worked on several new build projects, most notably the early development of the 1275MW Grain CHP plant, and acted as interface between commercial functions (such as Strategy and Trading) and the power plant asset managers. Andy has 20 years of experience in the power industry, including design and operation of supercritical coal power plant, combustion technology and a stint on an operating coal-fired power station. In Andy’s current role, he is one of four directors responsible for the ROAD Project – a 250MW CCS demonstration in Rotterdam, due to be in commercial operation by 2015. He has responsibility for the engineering, design and construction of the Capture Plant including the interfaces with E.ON’s MPP3 Power Plant (the host for the CCS demonstration)
  • QUESTIONS  We will collect questions during the presentation.  Your MC will pose these questions to the presenters after the presentation.  Please submit your questions directly into the GoToWebinar control panel. The webinar will start shortly.
  • Flow Assurance & Control Philosophy Jan Uilenreef, Project manager Transport & Storage Webinar Global CCS Institute, 15 April 2014
  • Page 6 Agenda • Project Overview • Pipeline Routing (onshore/offshore) • Process Chain: from stack to well • Control Philosophy/Flow Assurance • Research Recommendations 6
  • Page 7 Agenda • Project Overview • Pipeline Routing (onshore/offshore) • Process Chain: from stack to well • Control Philosophy/Flow Assurance • Research Recommendations 7
  • Page 8 CO2 Streams Impurities of CO2 mixture N2 02 H2O Acetaldehyde Ar 350 ppmv 50 ppmw 50 ppmv 10 ppmv 7 ppmv
  • Page 9 Location of ROAD Project Port of Rotterdam and North Sea Shipping lane crossing Harbour crossing 25 km P18-A TAQA
  • Page 10 Location of Capture Plant: Maasvlakte Power Plant 3
  • Page 11 Agenda • Project Overview • Pipeline Routing (onshore/offshore) • Process Chain: from stack to well • Control Philosophy/Flow Assurance • Research Recommendations 11
  • Page 12 Design data of Road CO2-Pipeline • Diameter : 16 ” (400 mm) • Mechanical Design Pressure : 140 bar ga • Mechanical Design Temperature : -10 to 90o C • Wall thickness (approx.) : 20 mm • Soil cover minimum : 1 m • Insulation onshore (PUR/PE) : 50 mm • Insulation offshore (PUR/PE) : 30 mm • Horizontal Directional Drillings (HDD) : 2 • HDD system/steel-in-steel : 24/16 ” • HDD insulation : vacuum • HDD depth Yangtze Harbor : -39 m NAP (Dutch Reference level) • HDD depth Maasgeul : -38 m NAP
  • Page 13 Pipeline Routing
  • Page 14 Onshore Pipeline Route
  • Page 15 Layout of Expansion Loop
  • Page 16 The Maasgeul Crossing
  • Page 17 P18 Well Locations P18-04A2
  • Page 18 Final Well Design Tail Pipe
  • Page 19 Agenda • Project Overview • Pipeline Routing (onshore/offshore) • Process Chain: from stack to well • Control Philosophy/Flow Assurance • Research Recommendations 19
  • Page 21 Basic Control Flow Chart PC 3 PC 1 FC 1 D-1 CO2 stripper OVHD Accumulator C-1 CO2 Product Compressor E-1 CO2 Compressor Discharge Cooler Inlet Guide Vanes CW From CO2 Stripper OVHD 25 km CO2 Pipeline Minimum Flow Bypass Reservoir M CV 2 CV 1 CV 3 Basic Control Flowchart CO2 Compression, Transport & Storage To CO2 Absorber TC 1 Platform PC 2
  • Page 22 Typical Compressor Performance Curve
  • Page 23 Expected Operating Modes The operation of the capture plant is very dependent on the operation of the power plant as the power plant feeds directly into the capture plant and the transport and storage system: • The capture plant and the transport and storage operation should follow the operation of the power plant, as there is no intermediate CO2 buffer • The design of the transport and storage equipment and controls should take into account the normal and emergency start-ups and shutdowns both of the power plant and also the transport and storage system alone In all cases of normal operation, startup and shutdowns the transport system has to cope with safe and sound operation.
  • Page 24 Gravity and Friction Forces CO2 Stream
  • Page 25 Temperatures At Well As Function of Flow Rates
  • Page 26 Minimum Operating Temperature At Pipeline Inlet Reservoir Pressure [bara] PipelineInletTemperature[°C] Limitation by mixed flow (no platform valve) Limitation by min. downholeTemp (with platform valve) Pipeline 16", 25 km DT 80 °C, DP 140
  • Page 29 Mollier Diagram of CO2 4°C 40°C 80°C Operating Envelope 4°C
  • Page 30 Pressure-Temperature Relation for CO2
  • Page 31 Temperature Along Pipeline Length Temperature drop across tail pipe near bottom of well
  • Page 32 Pressure Along Pipeline Length Pressure drop across tail pipe near bottom of well
  • Page 33 Pipeline Content After Cool-down Of Full Pipeline
  • Page 35 Planned Start-up After Planned Shutdown Open PCV at pressure slightly above wellhead Monitor temperature at wellhead (>-10oC) and tailend (>+15oC) Increase flow to maximum values after all slugs have passed Well-head pressure < 40 bar Well-head pressure > 40 bar Pipeline should stay in gase phase Pressurize pipeline to pressure slight above well-head pressure. Pipeline will contain liquid Compress pipeline with hot gas
  • Page 36 Planned Shutdown Empty pipeline into the well with closed compressor discharge valve Close PCV before backflow from well may occur Heat pipeline content to max. temperature (80oC)
  • Page 37 Planned Start-up After Non-planned Shutdown by Platform Operation Short repair time expected Long repair time is expected Continue to fill pipeline with hot CO2 Shutdown of Capture Plant Pipeline cannot be emptied into the well After repair, restart operation of pipeline at low flow, speed up after slugs are passed Cooldown the pipeline content After repair, restore operation following Normal start-up
  • Page 38 Planned Shutdown After Emergency Shutdown by Capture Plant Operation Shutdown of com- pressor discharge valve before heating of pipeline content Pipeline may contain more CO2 and cooldown may take longer Pipeline may contain large amount of liquid after cool- down Monitor flow and temperatures at tail end to avoid vibrations
  • Page 39 Agenda • Project Overview • Pipeline Routing (onshore/offshore) • Process Chain: from stack to well • Control Philosophy/Flow Assurance • Research Recommendations 39
  • Page 40 Research Recommendations • It is recommended to further investigate the possibility that the CO2 can be injected without any heating, making sure that the slugs can be handled in the well piping • A positive outcome will result in the possibility to transport CO2 to low pressure field over larger distances and in pipelines without insulation
  • QUESTIONS / DISCUSSION Please submit your questions in English directly into the GoToWebinar control panel. The webinar will start shortly.
  • Please submit any feedback to: webinar@globalccsinstitute.com Full report available: http://www.globalccsinstitute.com/publications/road- project-flow-assurance-and-control-philosophy