CCS System Modelling toolkit project

© 2017 Energy Technologies Institute LLP - Subject to notes on page 1

Alfredo Ramos

PSE

CCS System Modelling toolkit

project


© 2017 Energy Technologies Institute LLP The information in this document is the property of Energy Technologies Institute LLP and may not be copied or communicated to a third party, or used for any purpose other than that for

which it is supplied without the express written consent of Energy Technologies Institute LLP.

This information is given in good faith based upon the latest information available to Energy Technologies Institute LLP, no warranty or representation is given concerning such information,

which must not be taken as establishing any contractual or other commitment binding upon Energy Technologies Institute LLP or any of its subsidiary or associated companies.

Alfredo Ramos PlasenciaVice President Strategic Business Development

CCS System Modelling Toolkit (SMTK) ProjectPSE E4Tech E.On EDF CO2DeepStore Rolls-Royce


Outline

• PSE background

• CCS System Modelling Toolkit project

• Impact

• Summary


Private, independent company

incorporated in UK

1997

Company ‘spun out’

Acquires technology

PSE HISTORY: FROM RESEARCH TO INDUSTRY

Advanced Process Modelling• Software and services (60:40)

• Major process industry focus – all sectors

• Strong R&D, strong commercials

1989 – 1997 Now

Advanced Process Modelling platform

100s of person-years of

R&D with industry

Simulation & modelling,

optimization, numerical

solutions techniques,

supply chain

London HQ Korea JapanUS NJUS TX Switzerland

Thailand Malaysia ChinaTaiwan


Royal Academy MacRobert Award for Engineering Innovation

UK’s highest engineering award

Previous winners include: Microsoft, IBM, Johnson Matthey, Rolls-Royce, BP

Fuel Cells & BatteriesHigh-fidelity component and system models

Oil & GasUpstream, Midstream, LNG

Energy & EnvironmentPower, Water, Carbon Capture & Storage

Chemicals, Petrochemicals & RefiningRefining , Gas-to-Liquids, Olefins, Intermediates & Derivatives, Polymers, Bulk Chemicals, Metals

Formulated ProductsPharmaceuticals, Food, Personal & Home Care, Speciality Chemicals


Power generators 1

Compression & transmission 3

Industrial gas companies 2

Process providers

2

CO2 Users and Storage providers

4

+

Enabling organisationsGovernment & Regulatory authoritiesEngineering companies, consultantsUniversities, research organisations

5

CCUS challenges – stakeholders


Challenges

• Flexibility – how to design for & operate ‘flexible’ CCS-enabled fossil power generation plants and

CCS networks?

• Transferability of experience/expertise – how can we translate experience from one large-scale

integrated project to the next?

• Cost – Abatement cost of CCS perceived as too high with respect to other low-carbon

technologies/ renewables

• ‘Interconnectedness‘ – changes in the operation of one element of the CCS chain affect all of its

constituents


Grid demandFlexibilityEfficiencyFuel mixTrip scenarios

SizingFlexibilityBuffer storageAmine loadingCapital cost optimizationEnergy sacrificeHeat integrationSolvent issues

Optimal operating pointEfficiencyNew designImpuritiesControlSafety

Composition effectsPhase behaviourCapacityBuffering / packingRoutingSafetyDepressurisationControlLeak detection

CCS challenges

Multiple stakeholders with different issues & challenges

GovernmentPolicyStrategicInfrastructure developmentH&S

CompressionSupply variabilityCompositionThermodynamicsTemperatures / hydratesWell performanceLong-term storage dynamicsBack-pressures

Injection/storage

…currently being addressed by individual tools


• CCS System Modelling Tool-kit

Project

– £3.6m project

– 3 year development (2011-2014)

– Tool tested using several case

studies provided by consortium

membersCreate a commercial Model-based decision Support tool

built on PSE’s gPROMS platform

capable of modelling the operation of full-chain CCS systems or subsets of such systems

high-fidelity “end-to-end” CCS modelling tool

Modelling technology & expertise

Management


CCS System Modelling Tool-Kit – Project Review

Project structure

WP6

WP5WP4

WP3

WP2

WP6.1Streamline model

libraries

WP6.2Productisation

(installer, licensing, etc.)

WP6.3Training/tutorials

WP5.1 Case study 1

WP5.2 Case study 2

WP5.3 Case study 3

WP5.4 Case study 4

WP4.1 Develop interfaces for procedural code

WP4.2 Develop interfaces/translator for declarative code

WP4.3 Demonstrate model fitting

approach for compressor model

WP4.4 Documentation / tutorials

WP4.4 Documentation / tutorials

WP3.1 Establish thermodynamic

systems

WP3.2 Estimation of phys prop parameters / tool implementation

WP3.3 Documentation & reporting

WP2.1(a) PC & common components

WP2.2 CO2 Capture

WP2.3 CO2 Compression

WP2.4 CO2 Transport/Injection

WP2.5Oxyfuel PC /

IGCC

WP2.1(b) CCGT



Internal project teams

Compression Systems

Taskforce

PSE

Javier Rodríguez

Elton Dias

Mario Calado

Nouri Samsatli

Alfredo Ramos

Rolls-Royce

Carrie Lambert

Thierry Moes…

Power Systems Taskforce

EDF

Eric Joos…

E.ON

Amy Woolley

Laurence Robinson

…

PSE

Nouri Samsatli

Adekola Lawal

Gerardo Sanchís

Ricardo Fernandes

Hugo Rodrigues

Alfredo Ramos

Capture Systems

Taskforce

CO2DeepStore

EDF

E.ON

PSE

Rolls-Royce

Transmission/ Injection

Taskforce

CO2DeepStore

EDF

E.ON

PSE

Rolls-Royce



Project timeline



Project planning


gCCS v1.1 scope

• Process models

– Power generation• Conventional: PC, NGCC

• Non-conventional:

oxy-fuelled, IGCC

– Solvent-based CO2 capture

– CO2 compression &

liquefaction

– CO2 transportation

– CO2 injection in sub-sea

storage

– CO2 Enhanced Oil

Recovery

• Materials models

– cubic EoS (PR 78) • flue gas in power plant

– Corresponding States

Model• water/steam streams

– SAFT-VR SW/ SAFT- Mie• solvent-containing streams in CO2

capture

– SAFT- Mie• near-pure post-capture CO2 streams

Open architecture allows incorporation of 3rd party models

Costing models Equipment CapEx & OpeX


Governor valve

Feed Water Heaters

Deaerator Condenser

Generator

Coal

Air

Boiler

Turbine sections

Flue gas treatment

gCCS Power Plant Library – conventional power generation

Supercritical pulverized coal power plant


gCCS Power Plant library – conventional power generation

NGCC power plant

Gas Turbine

Condenser

Generator

Steam turbines

Steam drums

Economisers, superheaters, evaporators

Input flexibility:Total power output or natural gas flowrate specified

Air

Natural Gas

Steam to Capture Plant

Condensate return

Stack


• Oxyfuel - Process side

Ste

am c

ycle

gCCS Power Plant Library

Non-Conventional Generation


• Oxyfuel - Steam Cycle

Pro

cess

sid

e

gCCS Power Plant Library

Non-Conventional Generation


gCCS solvent-based CO2 capture modelling framework

Process and material models

gCCS process models

gSAFT material models


Multi-section compressor trainIncluding Control System

Accurate physical properties

Interface with “in-house” tools Performance map flexibility

Surge and pressure control


Transmission and Injection

Injection Well

Pipelines – including topography

ESD valves

Gate Valve

Risers

CO2 Flowmeter

Distribution header

Choke Valve

Reservoir

Wellhead connection


CO2 Enhanced Oil Recovery

Surface facilities

Sub-surface facilities

Fresh CO2 supply

Produced waterProduced crude oil

Produced sales gas

Water injected

Gas treating unit

Membrane

Cooler

CO2 Pump

CO2 compressors

Three phase

separator

Reservoir

Production

well CO2

injection well

Water

injection well


Offshore dense-phase injection; 4 injection wells

~2km reservoir depth(acknowledgement:

CO2DeepStore)

220km of pipelineOnshore and Offshore

~800MWe SupercriticalPulverized coal(acknowledgement: E.ON)

4 compression trains2 frames per trainSurge control(acknowledgement:Rolls-Royce)

Chemical absorptionMEA solvent90% CO2 capture

Single CCS chain model in gCCS


CCS network modelling in gCCS

Reservoir A

Reservoir B

NGCC

PC plant

11km

280km

80km

101km

Amine Capture Unit

CO2 Compression Unit


Load disturbance in CCGT


Load change effects

An increase of about 62% in the CCGT onshore pipe flowrate only increases 1.8% the inlet flowrate of the onshore pipe


Industrial projects

Optimizing start-up and shutdown procedures of gas treating plants[Shell]

CCS chain and network studies [Energy Technologies Institute and Shell]

Techno-economic study of Industrial Carbon Capture and storage [DECC and Element Energy]


CAPSULE (UK Government/ Carbon Clean Solutions)

Specific Project Objectives• Reduce the solvent regeneration energy

footprint by up to 40% as compared to a

standard/current MEA process.

• Demonstrate zero solvent emissions from

carbon capture plant.

• Reduce corrosion rates to migrate to

inexpensive material of construction.

• Focus on process standardization,

intensification and industrial scale up. Reduce

the overall level of plant redundancy and

overdesign to account for outage and

performance risks in the future CO2 capture

systems.

• Development of high-fidelity predictive

models for optimising the design and

operation of the full-scale plant in order to

realise the full extent of these savings.

Benefits• The novel APBS solvents reduce the steam consumption

by upto 40% which translates to an approximate 22%

reduction in LCOE (levelised cost of electricity) for a CCS

enabled power plant.

• Auxiliary electrical load, which consists mainly of pumps

and fans, can be reduced by 50%.

• Improved process layout, which maximizes sharing of

infrastructures and mitigation of expensive connections.

• Process standardization, better layouts and best metering

technology selection will boost the confidence in future

leading to savings realization between 5% - 7%. Also

reduced redundancy and overdesign will reduce the risk

premium leading to savings between 2% - 4%.


For Accelerating Technology Development

National Labs Academia Industry

Rapidly synthesize

optimized processes

to identify promising

concepts

Better understand

internal behavior to

reduce time for

troubleshooting

Quantify sources and

effects of uncertainty to

guide testing & reach

larger scales faster

Stabilize the cost

during commercial

deployment

U.S. Carbon Capture Simulation Initiative (CCSI)


CCS System Modelling Tool-Kit

Model Development Workflows

Model Validation

PSE

Establish key model inputs and KPIs

Define user interface (icon, ports, specification dialog)

Pass formal review?

yes

no

Run predictive simulations for other datasets and cross-check

Data processing

Tech Spec

Model specification

document

Define test cases for stand-alone model testing

Test Data

Implement core model/ customise interface to gPROMS / Implement gPROMS user interface

Review interface

Pass formal review?

Review model/ interfaceimplementation

Model verified?

Chief Technologist

yes

no

yes

no

Model documentationE.ON

Validation Data

Data processing

VerificationData

Implement and run test cases

Define interface to proprietary models (interfacing protocols,

templates, translator, etc.)

Implement interfaces to proprietary models

no

Review model

Model Validation / Parameter Estimation

PSE

Define user interface (icon, ports, specification dialog)

Pass formal review?

yes

no

Run predictive simulations for other datasets and cross-check

Data processing

Tech Spec

Model specification

document

Define test cases for stand-alone model

testing

Test Data (literature)

Test Data Implement core model

and user interface

Review modelling approach

Implement and run test cases

Pass formal review?

Develop and implement initialisation procedures (if necessary)

Review model implementation / Model refinement (e.g. Improve

thermodynamic calculations, etc.)

Model verified?

Chief Technologist

yes

no

yes

no

TTCM

TTCM

Model documentation

CO2DeepStore, EDF, E.ON, Rolls-Royce

Validation Data

VerificationData

Confirm validity of model definition / Establish model equations based on key

inputs, KPIs and the model’s physical basis

Data processing


PSE Team


Summary

The CCS SMTK project gave us…

• A product - a unique engineering & simulation

tool ready to be marketed

• Workflows & procedures essential for a

growing company to firm up its internal &

external delivery

• Access to world-class expertise from ETI’s

members and worldwide, top tier client base

• Skilled people

– priceless!!


Acknowledgements

• This work was carried out as part of a £3.6m

project commissioned and co-funded by the

Energy Technologies Institute (ETI) and

project participants E.ON, EDF, Rolls-

Royce, CO2DeepStore, PSE and E4tech.

• The project is aimed at delivering a robust,

fully integrated tool-kit that can be used by

CCS stakeholders across the whole CCS

chain.

• Andrew Green, Programme

Manager


© 2017 Energy Technologies Institute LLP The information in this document is the property of Energy Technologies Institute LLP and may not be copied or communicated to a third party, or used for any purpose other than that for

which it is supplied without the express written consent of Energy Technologies Institute LLP.

This information is given in good faith based upon the latest information available to Energy Technologies Institute LLP, no warranty or representation is given concerning such information,

which must not be taken as establishing any contractual or other commitment binding upon Energy Technologies Institute LLP or any of its subsidiary or associated companies.

Thank you

CCS System Modelling toolkit project

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