gccs –whole-chain ccs system modelling · ©2013 process systems enterprise limited activities...

© 2012 Process Systems Enterprise Limited

UKCCSRC Systems Modelling

30 January 2013

Alfredo Ramos – Head of CCS Business

Mark Matzopoulos – Marketing Director

gCCS – whole-chain CCS system modellingAccelerating deployment and managing risk

A g P R O M S P L A T F O R M P R O D U C T

THE ADVANCED PROCESS MODELLING COMPANY


Overview

1. Process Systems Enterprise (PSE)

2. Challenges in commercialising CCS

3. CCS System Modelling Tool-kit Project

4. gCCS demo


Private, independent company

incorporated in UK

1997

Company ‘spun out’

Acquires technology

HISTORY: FROM RESEARCH TO INDUSTRY

� Software and services (60:40)

� Major process industry focus – all sectors

� Strong R&D

� Strong commercials

1989 – 1997 2012

Royal Academy MacRobert Award for Engineering Innovation

UK’s highest engineering award

100s of person-years of

R&D with industry

Simulation & modelling,

optimisation, numerical

solutions techniques,

supply chain

London HQ Korea JapanGermanyUSA

IndiaSaudi Arabia Thailand Malaysia China


Global customer base (partial)

AmericasAir Products

BP Chemicals

Carus Corporation

CD Tech

C&I Engineering

ConocoPhillips

Dow Chemicals

DuPont

ExxonMobil

Ineos

Praxair

Eli Lilly

Energy Solutions

Folgers

Johns Manville

Minera EXAR

Procter & Gamble

Pfizer • SQM

Toyota Motor US

United Technologies RC

United Technologies Power

EMEAArkema • AstraZeneca

BP Chemicals

BP Exploration

BASF • CEPSA

E.On • EDF

Infineum • Indorama

Jacobs Engineering

Linde • Petrofac

Repsol • SABIC • SASOL

Shell • Siemens VAI •

Süd-Chemie • Sulzer

TOTAL • Wacker Chemie

Wolff Cellulosics

Anglo Platinum

AstraZeneca

Atomic Weapons Est.

Cadbury’s • Ceres Power

det Norske Veritas

Energy Technologies Institute

FL Smidth • Friesland Campina

GSK • National Nuclear Labs

Nestlé • Purac

Veolia • Voith Paper

APAC

Idemitsu Petrochemicals

GS E&C • Hyosung

JGC • LG Chem

Mitsubishi Chemical

Posco •

Samnam Petrochemical

Samsung BP

SKC

SK Chemicals

SK Energy

SK Petrochemicals

Taiyo Nippon Sanso

Denso • KIER

Samsung Electronics

Samsung SDI

Sugar Australia

Toshiba Fuel Cell

Honda • Toyota CRDL

Toyota Motor Company


Carbon capture & storage

CommercialisationRisk

Acceleration

Energy penalty/efficiency

Integration/interoperability

Trust


Power

generators

1

Industrial gas

companies2

Compression &

transmission

3

Process

providers2

Storage

providers

4+

Enabling organisationsGovernment & Regulatory authorities

Engineering companies, consultants

Universities, research organisations

5

CCS challenges – stakeholders


Sizing

Flexibility

Buffer storage

Amine loading

Capital cost

optimisation

Energy penalty

Heat integration

Solvent issues

Optimal operating

point

Efficiency

New design

Impurities

Control

Safety

Composition effects

Phase behaviour

Capacity

Buffering / packing

Routing

Safety

Depressurisation

Control

Leak detection

Compression

Supply variability

Composition

Thermodynamics

Temperatures / hydrates

Well performance

Long-term storage

dynamics

Back-pressures

Tools

PROATES

Dymola

GTPro

Aspen Plus

Tools

gPROMS

PROMAX

Aspen Plus

Tools

Various in-house

Tools

OLGA

Tools

OLGA

Prosper/Gap

CCS challenges

Each stakeholder has different issues & challenges

Government

Policy

Strategic

Infrastructure development

H&S

BUT!

All interconnected

Specific challenges

Addressed by point solutions

And different tools …


Challenges – single site

HP

ASU

LP

Energy integration

(energy penalty vs

operability vs CAPEX)

Rich amine storage –

how much, when,

where? Temperature?

Performance of

different capture

technologies – amine

vs caustic vs ?

By-pass economics

Start-up sequence –

economic optimisation

Post-combustionVent?

How much? How long

permitted? What is policy?

Reboiler size – hot buffer

storage ?

Energy integration

- technicalities

Dynamics

– ramp-up /

down capability?

CO2 breakthrough?

Much scope for

optimisation / new

solvents / new

technologies

Inlet flow

control?

Exit flow

control?

Effect of downstream trip?

High pipeline pressure?

Start-up policy?


Many questions

HP

ASU

LP

Performance

optimisation for

strongly time-varying

operations

Technologies? IGCC,

Oxyfuel, IGFC, ?

Pre-combustion

Gasifier design

& integration

questions

ASU dynamics?

Ramp-up, ramp-

down

Flexibility; start-

up & shutdown

policy

ASU buffer

storage? Ramp-up,

ramp-down

Effect of downstream

trip? High pipeline

pressure?


Many questions

HP

ASU

LP

Phase boundaryCost/performance

optimisationCompressor efficiency

Optimised operations

w.r.t power station

operating point

Network configuration?

Construction sequence?

Economics of decisions?Compression & transmission

Safety

phase change,

temperature issues

Pressurise pipeline?

Capacity? Temp on

depressurisation?

Economics?

Buffer storage?

Cost vs reliability /

operability trade-offs?

Impurity propagation

Line packing capacity

Pressure control

Buffer storage design

& operationComposition effects

Sizing

Flexibility

Energy penalty / sacrifice

Operating point? Heat

integration?


Many questions

HP

ASU

LP

Pre-injection heating vs line

pressurisation?

HP v LP

development

economics

Performance

optimisation

Trip scenarios –

economic effects and

trade-offs

Phase considerations?

Hydrate formationInjection & storage

Minimum &

maximum rates

Safety

Operational choices -

switch reservoir from

HP to LP? Hydrate

formation?

Phase transition

Joule-Thomson

effects – hydrate

formation

Compression

economic &

control issues

Startup from cold

Quantification of heat

transfer

Impurities affecting

critical point


Whole-chain control issues

HP

Control design & verification

ASU

LP

Physical properties, thermodynamics

System-wide economics


In summary

1. Many questions

2. Lots of trade-offs

3. Technical closely related to economic

4. Areas cannot be considered in isolation

5. Need to be answered quickly

Commercialisation


Putting these all together …

System-wide modelling is a key

technology for addressing these questions

and investigating whole-chain or partial-

chain interaction

… by providing accurate quantification for

decision support


CCS System Modelling Tool-kit Project

Meeting the challenge with commercially-

available software


System-wide modelling: high-level

requirements

� CCS System Modelling Tool-kit Project

− Energy Technologies Institute (ETI)

£3m project

− E.ON, EDF, Rolls-Royce,

Petrofac/CO2DeepStore, PSE, E4tech

gPROMS modelling platform

technology & expertise

Management

�Create a commercially available product

− built on PSE’s gPROMS platform

− High-fidelity system-wide CCS modelling

− Toolbox and ecosystem


Basic requirements for system modelling

� Models

− set of models covering key

components along the chain

− right level(s) of fidelity

− steady-state and dynamic

− accurate physical property

models

− multiple scale – from

microscale to network

� Solution power

− rapidly solve large-scale

problems

− robust problem initialisation

− optimisation, not just

simulation

� User environment

− drag & drop flowsheeting

− custom modelling

� External

− incorporate models from

other environments

− export models to other

environments

� Commercials

− Commercially available

− Support & training

− 3rd-party integration

− ‘Ecosystem’


Environment – custom & system-wide modelling

Flowsheet

representation

[Optional] custom

model construction

CCS model

libraries

Hierarchical models

– “drill down”

Steady-state &

dynamic Results

management

Operating

procedures

Specification

dialog

Whole-system flowsheeting

Add custom

models of new

processes


Environment – custom & system-wide modelling

Model equations

Project tree view

Call to physprops

Dynamic mass balanceModel ‘packaging – icon, ports

& specification dialog

Implemented in library for

access by other users

Powerful custom modelling


gCCS – The tool-kit

Demonstration


Whole-chain example – I


Whole-chain example – II


Whole-chain example – III


Universal system modelling tool: key benefits

� Explore complex decision space rapidly based on high-fidelity,

technically realistic models

− resolve own technical and economic issues

− take into account upstream & downstream behaviour

� Manage interaction and trade-offs

� Evaluate technology – existing and next-generation

− judge relative merits of emerging technologies

− support consistent, future-proof choices

� Integrating platform for

− working with other stakeholders in chain

− collaborative R&D, working with academia

Manage complexity and risk at a multi-scale,

network-wide level��


When?

� Now

− Conventional power (PC, CCGT), CO2 capture (chemical

absorption), compression & transportation/injection models

delivered to project partners

− Available to universities & research consortia

− Components available for evaluation to selected lead users

− Interfaces to 3rd-party models

� Soon (3-6 month timescale)

− IGCC, oxyfuel power generation

− Capture – physical absorption

− SAFT-γ Mie integration

� To follow (6 month – 1-year timescale)

− Project-ready environment


Activities & dates

� Academic programme

− University liaison – key universities

− Adekola Lawal – [email protected]

� PSE Advanced Process Modelling Forum, London

− CCS & Power hands-on workshop – all day 17 April 2013

− CCS & Power session (presentations) – 18 April 2013


Thank you!


PSE products

The gPROMS platformUnified modelling platform

across all products

General-purpose

Advanced Process ModellingPowerful custom modelling in a

flowsheeting environment

Advanced Model LibrariesWorld-leading models for reaction

& separation

gPROMS platform productsDomain-specific tools for specialists

The gPROMS

product family

General Process

Engineering suite

gCCS

gccs –whole-chain ccs system modelling · ©2013 process systems enterprise limited activities...

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