The document details the PACT carbon capture plant's specifications, design, and operational capabilities in Sheffield, including its integrated systems for capturing CO2 from various flue gases. It outlines the plant's operational statistics, initial testing results, and various applications aimed at optimizing carbon capture technology. Furthermore, the document highlights recent upgrades and enhancements aimed at expanding the plant's research capabilities and improving data accuracy.

1. PACT CARBON CAPTURE PLANT
PACT OPENING
Advanced Manufacturing Park, Sheffield
20/06/2014
Dr Kris Milkowski
Dr Muhammad Akram

2. •
Solvent based carbon capture plant for capture of CO2 from combustion flue/process gases
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Operates in an integrated system with:
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330kW Gas Turbine
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250kWth PF (Coal/Biomass) rig
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Synthetic flue/process gas mixing facility
Overview

3. •
Comprises:
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8m/300mm Absorber/Desorber
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Water wash column
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Integrated FGD (carbonate)
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Treats 210 Nm3/h of flue gas
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Removes 1 tonne of CO2 per day (Coal flue gas with MEA)
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Equipped with:
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Gas analysis for monitoring flue gas inlet and outlets from absorber, desorber and water wash
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Solvent sampling on columns
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Material corrosion testing
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Trace gas injection capability
General Specification

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Testing & development of alternative capture solvents.
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Benchmarking & energy requirements
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Solvent degradation & enhancement
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Assessment of plant and integrated system flexibility
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Fuel testing
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Integrated systems modelling and control
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Validation of baseline economics
Example Applications

5. Operating principles

6. Integrated facilities
250kW PF Rig

7. PF rig – Carbon Capture Plant
Example Applications
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Post Combustion Capture research from:
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Coal
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Biomass
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Co-firing
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Natural gas
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High oxygen firing
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Impact of trace gasses on solvent stability
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Integrated system modelling
Integrated System Specification
•Portion (150kW eqiv.) of flue gas treated
•Flue gas filtered & cooled by 2 heat exchanger
•FGD package:
–DCC
–SOx reduction to ~10ppm

8. Gas Turbines - Carbon Capture Plant
Example Applications
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Post combustion capture research for gas turbines
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Development of FGR technology
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Impact of transient operations
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Integrated system modelling
Specification
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Portion of flue gas treated by Carbon Capture Plant
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FGD by-passed
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CO2 Concentration 1.5%;
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Flue gas modulation through CO2 and/or N2 injection

9. Specification
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Gas metering and mixing skid for O2, CO2 and N2 fed from cryogenic storage tanks.
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Complemented by trace gas injection.
Applications
•Synthetic flue/process gasses
•Modulation of flue gases from PACT facilities to mimic specific gas concentrations.
•Bespoke solutions for CO2 capture from power generation and industrial processes
•Evaluation of the impact and system flexibility for different process conditions/fuels
•Mechanistic solvent stability studies
Gas Mixing Facility

10. History
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Plant donated from RWE npower (Didcot) Feb 2012
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Installation commenced Mar 2012
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Installation completed and commissioning commenced in Dec 2012
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Experimental operation August 19th 2013
RWE npower Didcot 2008
PACT, April 2012
PACT, August 2013

11. Operational stats
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Until end of March 2014 (~7months) completed over 1200 operating hours on the Carbon Capture Plant (combination of 24 and 8 hr operations)
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Longest continuous operation: 18 days
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Primarily industrial R&D
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Testing:
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MEA
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Novel commercial solvents

12. Sample Results

13. Initial testing
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MEA 35%
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6 days continuous run
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Testing operation and capture performance
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Flue gas from Gas turbine, modulated with CO2 injection to 4.5% - 11.5% CO2
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Solvent flow rate 950-500kg/h

14. Solvent concentration variations
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Solvent concentration changes against running time
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No fresh solvent was introduced
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Solvent concentration decreased slightly with time
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Both rich and lean are similar
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5
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100
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Amine Concentration (%)
Runining hours
Rich amine
Lean amine

15. Wash column performance
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Solvent concentration in the wash column as a function of time
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The concentration increases although fresh water is introduced
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Water consumption rate 6 l/h at 4.5% CO2, 12 l/h at 8% CO2 concentration in the flue gas
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0.5
1
1.5
2
2.5
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Amine Concentration (%)
Running hours
Filled fresh water

16. CO2 loadings
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Rich and lean loadings against time
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0.05
0.1
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0.2
0.25
0.3
0.35
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100
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CO2 Loadings (mol CO2/mol MEA)
Running hours
Rich
Lean

17. Capture plant performance
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30
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Captured CO2 fraction
L/Kg CO2
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8
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Captured CO2 fraction
Energy input boiler (GJ/tonne CO2)

18. Plant development
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Following initial testing the plant has been significantly upgraded to expand and automate data recording :
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New temperature & pressure sensors across column and cross exchanger
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Heat flow measurements
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Enhanced gas flow measurments

19. Plant development
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Enhanced gas analysis: New CO2 analyser
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Emissions monitoring: GASMET FTIR monitoring water wash inlet and outlet
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Liquid analysis by GCMS

20. Acquisition of Ferrybride Pilot CC100+ Equipment
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Online monitoring equipment:
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GASMET FTIR and 5-chanel heated sampling system
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Metrohm Applickon AD 12045TL Process analyzer
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Siemens ammonia analyser
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CO2 and O2 analyser
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Laboratory facilities
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Auto-titrator
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Ion chromatography
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Laboratory equipment
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Plant instrumentation
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Density meters, conductivity probes
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Pressure sensors and DPs
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Temp. sensors
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Flow meters ( liquid and gas),…

21. Further development
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New absorber column packing in partnership with Sulzer
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New zero emissions wash column
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Structural plant modifications to extend operating capabilities and deliver better data for modelling
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Enhanced control system (flexibility)

22. Summary
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Integrated 1 tonne/ day carbon capture plant
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Variety of flue gases: GT, PF rig & Gas Mixing Facility
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Open access for industry and academia
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High level of utilisation
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Upgrades to enhance research capability and international standing