feed study of 110,000 tpa post-combustion capture plant
TRANSCRIPT
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FEED Study of 110,000 tpa Post-Combustion
Capture Plant for the Australia Surat Basin
Integrated CCS Project
澳大利亚苏拉特盆地CCS项目十万吨级燃烧后捕集系统
前端工程设计
Dr. Shiwang Gao
China Huaneng Clean Energy Research institute
Kyoto, Japan
2019-9-17
CONTENT 目录
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Overview of CERI 清能院简介
Project Background 项目背景
Project Execution Plan 项目实施情况
FEED Engineering Summary 工程设计概要
Future Work 未来工作计划
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Overview of CERI 清能院简介
中国华能集团直属清洁能源前沿技术研发机构
Institution focused on the frontier technology research and development of clean energy.
主要研发领域 Mainly focuses on research of the following aspects
近零排放燃煤发电、煤气化及煤基清洁转化（Nearly zero emission for coal-fired
power generation; Coal gasification and clean coal-based energy conversion）
大型循环流化床锅炉、低质煤利用（Large–scale circulating fluidized bed boiler;
Low-quality coal utilization;）
可再生能源发电、发电新材料、能源系统设计优化（Renewable energy power
generation; Design and optimization of energy system）
CO2捕集、利用和封存（Capture, utilization and storage of CO2）
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CERI on Carbon Capture 清能院碳捕集发展里程碑
在华能北京热电厂建成我国第一个燃煤电厂碳捕集示范装置，规模为3000吨/年
2008
实验室规模测试与筛选实验
2009
在华能上海石洞口第二电厂同步建成当时世界上最大的燃煤电厂碳捕集示范装置，规模为12万吨/年
2011
在华能秦岭电厂建成第一套可移动式燃煤电厂碳捕集测试平台，规模为300吨/年
在华能长春热电厂建成一套可移动、带CO2超临界压缩的碳捕集测试平台，规模为1000吨/年
2013
2014
在北京未来科技城建成世界领先的碳捕集技术开发实验室
在密云建成第一套燃气烟气CO2捕集中试平台，规模为1000吨/年
Lab-scale
Study
China’s first CO2 capture
facility in Huaneng Beijing
Cogeneration Power Plant,
3000t/a
The largest CO2 capture
facility in Huaneng Shanghai
Shidongkou NO.2 Power
Plant, 120000t/a
The first removable
CO2 capture facility
in Huaneng Qinling
Power Plant, 300t/a
A removable CO2 capture
and compression facility in
Huaneng Changchun Power
Plant, 1000t/a
Advanced Laboratory
in Beijing
The first CO2
capture facility
for NGCC
Overview of Surat Basin CCS Project 苏拉特项目简介
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Surat Basin has 3 billion tonnes of CO2 theoretical
storage potential
二氧化碳理论储存量近30亿吨
Three existing coal-fired power stations closer to
the Surat Basin, inlcuding Huaneng’s Millmerran
Power Station
附近有3个燃煤电厂，包括华能M电厂
Deliver an integrated Carbon Capture and Storage
(CCS) Project incorporating carbon capture,
transport and sequestration in the Surat Basin.
项目目标是开发包含二氧化碳捕集、运输和封存全流程的CCS示范项目
Black Coal Industry (ACALET) and Australian
Government Funded Project，led by Glencore
through CTSCo (100% Glencore) as the Proponent.
项目由澳洲煤炭工业协会和澳大利亚政府资助，由Glencore全资子公司CTSCO管理。
Overview of Surat Basin CCS Project 苏拉特项目简介
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Feasibility/FEED study of the Integrated Project, including the FEED of PCC plant, is completed at the end of 2018.
全流程CCS项目的前端工程设计（含碳捕集装置）已于2018年底完成； The construction of the CCS demo project is planned to be completed by 2021/2022. 项目预计于2021/2022年建成； Injection capacity is 60ktpa for the first 3 years and then increase to 120 ktpa. 开始3年年注入量预计为6万吨/年，然后扩大到12万吨/年
Schedule of Surate CCS Project
项目开展进度和工作计划
Scope of FEED Engineering - 工程设计范围
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Flue Gas Desulfurization (FGD)
CO2 Capture Process(CCP)
CO2 Post-Treatment(CPT)
Millmerran Power Station
PCC Plant
System Integration
工程设计范围涵盖：（1）PCC装置：FGD（因为电厂没有脱硫）, CCP和CPT三个部分（2）PCC和电厂的系统集成
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Executive Parties & Roles - 项目分工
CERI MPSAECOMCTSCo
Overal Project
Management
项目管理Design Review
设计审查HAZOP
风险分析
Process Design
工艺设计 Facility Design
设施设计 Cost Estimate
设备造价估算 Preliminary
Management
Plan
管理方案 HAZOP
风险分析
Site geological
exploration
地勘 Cost Estimate
(EPC)
EPC估价 Design Review
Against AS
设计审查 HAZOP
风险分析
Technical Support
技术支持HAZOP
风险分析
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kick-off meetingApril 2018, Beijing
项目启动会
Process Design BriefingJune 2018, Brisbane
工艺设计汇报
Onsite Data AcquisationJune 2018, Brisbane
现场数据收集
HAZOP meetingOct, 2018风险分析
2nd Review meetingSep, 2018
设施设计审查
Project Timeline - 项目重要节点
1st Review meetingJuly 2018
工艺设计审查
FEED Study CompletedDec, 2018
设计完成及汇报
Post-FEED Study March, 2019完成设计优化
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Desgin Basis 设计基础
Item Remark
Feedstock-Flue Gas 烟气参数
- Temperature
- Flow Rate
- CO2 Concentration
- SO2 Concentration
150℃
73,000 Nm3/h
12%
1300 mg/Nm3
Product-Liquid CO2 产品参数
- Temperature / Pressure
- Production Rate
- CO2 Concentration
- Impurities
-20 ℃/ 2.5 MPa
13.75 tph/110,000 tpa
> 99.9%
GB 1886.228-2016 (Appendix A1002)
Design Operating Hours 设计运行小时数 8,000hrs / 20yrs
Solvent Specification 设计溶液 HNC-5
Utilities 公用工程参数
- Steam
- Electricity
- Cooling Water
215 ℃/13.6 MPa
6.6 kV, 415/240V
35℃(inlet) / 45℃(outlet)
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Process Design 工艺设计
Flue gas desulfurization （FGD)
Limestone-gypsum wet FGD with additional Flue Gas Cooler is
selected to remove SO2 and to cool the flue gas.
采用传统石灰石-石膏法脱硫，外加辅助烟气换热器。
CO2 Capture Process (CCP)
Amine-based chemical absorption technology is selected due to low
technical risk and available industrial experience.
考虑到技术风险较低，决定采用有机胺化学吸收法碳捕集工艺。
CO2 Post Treatment (CPT)
Food grade liquid CO2 with truck transportation is selected based on an
overal consideration of CAPEX、OPEX and CO2 market.
综合考量了造价、运行成本以及二氧化碳市场，决定生产食品级液态二氧化碳，采用罐车运输。
The PCC Plant is divided into 3 Processes:
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Process Design 工艺设计
Aspen Plus Models are designed to calculate the Mmaterial &
Heat Balance (MHB) for FGD, CCP & CPT Unit
FGD
CCP (CO2 Capture Process)
CO2 Post
Treatment (CPT)
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PFD/PIDs - 工艺流程图和管道仪表图
A total of 11 PFDs and 35 PIDs are delivered.
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Site Condition - 项目选址
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Site Condition - 项目选址
The total occupation is 13,125m2 (175m x 75m), the PCC plant is divided to two
sections by an existing road in the power station. The section near the stack
contains the equipment of FGD and CPT process, and the control room. The other
section contains the CPT equipment as well as the air cooler.
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PCC Plant Layout - 平面布置图
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3D PCC Plant - 三维建模
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3D PCC Plant - 三维建模
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Equipment Design - 设备设计
Design of Standard Equipent is Provided by Vendors
标准设备的设计由厂家提供
Design of Non-Standard Vessels is Provided by CERI
非标塔器、罐体和容器等由CERI设计
FGD Scrubber脱硫塔
CO2 Absorber/Stripper吸收塔/再生塔
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Modulisation Design - 模块化设计
The PCC plant is manufactured in China and shipped to Australia
by Modules to reduce the onsite installation work.
碳捕集装置在中国生产，分成若干模块运往澳洲组装。
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Impact of PCC on MPS - 捕集装置运行对电厂的影响
Flue gas extraction: only 2.5% of the total flue gas is extracted, 90% of
which will be returned to the stack.
Steam exctraction: 25 t/h steam is extracted from the auxiliary steam
system. Impact on the turbine system is negligible. No impact on the
steam-water balance since the condensate will return to the drainage tank.
Electricity: an increase of 3.4 MWh on auxliary comsumption, lead to a
decrease of net generation.
Cooling system: independent air cooling system. No impact on MPS
cooling capacity.
Other consumption: the consumption of DI water, filtered water,
compressed air has negligible impact on MPS operation.
Waste: the ash-making system of MPS has the capacity margin for PCC
waste water and Gypsum-Slurry; the amount of solid waste is negligible.
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OPEX Study - 运行成本分析
OPEX = 69.45 AUD/tCO2
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CAPEX Study - 投资造价分析
The CAPEX of the PCC plant is divided to two major parts:
(1) The equipment package price is provided by CERI;
(2) The EPC price is provided by AECOM.
(3) The total CAPEX is not given for the business secret protection purpose.脱碳项目的造价被分为两部分：设备造价由CERI提供；EPC总包造价由AECOM提供。由于是商业机密，总造价这里没有介绍。
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MPS PCC vs. Shanghai PCC - 澳洲项目和上海捕集装置的比较
。
Features Shanghai PCC MPS PCC
Capacity Design 10 ktpa; Max. 12 ktpa. Design 11 ktpa
Product grade Food grade Food grade
Flue gas T=50℃SO2 < 30mg/Nm3 (after FGD)
CO2 ~ 12%
Emitting to air directly
T=150℃（much higher）SO2 ~ 1300mg/Nm3 (no FGD)
CO2 ~ 12%
Back to the stack
Overal Process CCP + CPT FGD + CCP + CPT
Cooling Cooling water Air cooler
Solvent HNC-5 HNC-5
Solvent
Reclaimer
Thermal Reclaimer Ion Exchanger
Waste
Treatment
Burn with coal Mixing with coal ash
Future Work - 未来工作计划
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The FEED Engineering work is completed. And the FEED Procurement is
almost done. The FID package is under preparation and will be delivered soon.
前端工程设计目前已完成，项目决策工作目前正在进行。 The Purchase\Construction\Commissioning of the PCC plant will be completed
in 3 years after the FID.
项目计划在决策后3年内完成采购、建造和投产。
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MILLMERRAN POWER STATION
Acknowledgment - 致谢！
Many thanks to all funders, partners and those who cares about
this project. 感谢项目资助方，项目合作伙伴以及关心该项目的所有人。
Thank you
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