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

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)

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Flow Assurance & Control Philosophy
Jan Uilenreef, Project manager Transport & Storage
Webinar Global CCS Institute, 15 April 2014

Agenda
• Project Overview
• Pipeline Routing (onshore/offshore)
• Process Chain: from stack to well
• Control Philosophy/Flow Assurance
• Research Recommendations
6

Agenda
7

CO2 Streams
Impurities of CO2 mixture
N2 02 H2O Acetaldehyde Ar
350 ppmv 50 ppmw 50 ppmv 10 ppmv 7 ppmv

Location of ROAD Project
Port of Rotterdam and North Sea
Shipping lane
crossing
Harbour
crossing
25 km
P18-A
TAQA

Location of Capture Plant: Maasvlakte Power Plant 3

Agenda
11

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

Onshore Pipeline Route

Layout of Expansion Loop

P18 Well Locations
P18-04A2

Final Well Design
Tail Pipe

Agenda
19

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

Typical Compressor Performance Curve

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.

Gravity and Friction Forces CO2 Stream

Temperatures At Well As Function of Flow Rates

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

Mollier Diagram of CO2
4°C
40°C 80°C
Operating Envelope
4°C

Pressure-Temperature Relation for CO2

Temperature Along Pipeline Length
Temperature drop
across tail pipe
near bottom of
well

Pressure Along Pipeline Length
Pressure drop
across tail pipe
near bottom of
well

Pipeline Content After Cool-down Of Full Pipeline

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

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)

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

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

Agenda
39

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

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Full report available: http://www.globalccsinstitute.com/publications/road-
project-flow-assurance-and-control-philosophy

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

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