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Global ccs institute aep feed webinar presentation
1. Mountaineer Commercial Scale CCS Project
Project Overview and Summary of FEED Activities
Global CCS Institute CO2 Capture Plant FEED Study Webinar
Presented By:
Matt Usher, P.E. & Guy Cerimele, P.E., P.M.P.
American Electric Power
December 15, 2011
American Electric Power: This presentation is provided “as-is” and with no warranties, express or implied, whatsoever for the use or the
accuracy of the information contained therein. Use of the presentation and the information found therein is at the sole risk of the recipient.
American Electric Power Company, its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in
the report, including but not limited to, any errors or omissions in any information content; or for any loss or damage of any kind incurred as
the result of the use of any of the information.
2. Acknowledgement
US Department of Energy:
National Energy Technology Laboratory (NETL) sponsored the project under Round Three of their
Clean Coal Power Initiative.
This material is based upon work supported by the US Department of Energy Award Number DE-FE0002673.
50% cost share
Integrated Project Team:
Alstom Power - Chilled Ammonia Process technology owner & conceptual design
WorleyParsons Group – Architectural & Engineering services for the balance of plant and CO2
pipeline engineering & design
Battelle Memorial Institute - CO2 storage scope
The Geologic Experts Team - Advisory body
Input to challenges, strategies, plans, designs, operations, results and recommendations of AEP and its
project team for injection and storage of CO2.
Global CCS Institute - Funding for project support and facilitation of knowledge sharing
American Electric Power: This presentation is provided “as-is” and with no warranties, express or implied, whatsoever for the use or the accuracy of the
information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 2
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
3. Disclaimer
Disclaimer
US Department of Energy: This report was prepared as an account of work
sponsored by an agency of the United States Government. Neither the United
States Government nor any agency thereof, nor any of their employees, makes any
warranty, express or implied, or assumes any legal liability or responsibility for the
accuracy, completeness, or usefulness of any information, apparatus, product, or
rocess disclosed, or represents that its use would not infringe privately owned
rights. Reference herein to any specific commercial product, process, or service by
trade name, trademark, manufacturer, or otherwise does not necessarily constitute
or imply its endorsement, recommendation, or favoring by the United States
Government or any agency thereof. The views and opinions of authors expressed
herein do not necessarily state or reflect those of the United States Government or
any agency thereof.
American Electric Power: This presentation is provided “as-is” and with no warranties, express or implied, whatsoever for the use or the accuracy of the
information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 3
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
4. Agenda
AEP & Mountaineer Plant Overview
Project Information & Objectives
Chilled Ammonia Process Overview
FEED Technical Objectives
Summary of FEED Activities
FEED Deliverables
Key FEED Studies & Investigations
Steam Supply and Condensate Return
Reagent / Refrigerant
Byproduct Bleed Stream Study
CO2 Compression Study
CCS Control Systems
FEED Conclusions & Key Technical Takeaways
Estimate Approach
Project Cost Estimate
Major Risks and Opportunities
Risk Modeling
Closing Remarks
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 4
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
5. AEP Overview
5.2 million customers in 11
states
Industry leading size and scale
of assets:
#2 Domestic generation with 38,000 MW
#1 Transmission with 39,000 miles
#1 Distribution with 216,000 miles
Coal & transportation assets
Over 7,500 railcars involved in operations
Own/lease and operate over 2,850 barges
& 75 towboats AEP Generation Capacity Portfolio
Coal handling terminal with 20 million
tons of capacity
Coal/ Gas/ Nuclear Other –
Lignite Oil (hydro, wind,
Consume 76 million tons of coal per year
etc.)
18,712 employees
66% 22% 6% 6%
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 5
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
6. Mountaineer Plant
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 6
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
7. Mountaineer Plant
Operated by Appalachian Power
Company, a subsidiary of AEP.
Located on State Route 62 near
New Haven, West Virginia
A single 1300 MW net pulverized
coal plant
Emission Controls
ESP – Original Equipment
SCR – Installed 2001
FGD and SO3 Mitigation installed
2007
Primary fuel is bituminous coal
Host site for Alstom’s 20 MWe
Product Validation Facility (PVF)
for Chilled Ammonia
Two (2) onsite CO2 injection wells
Operated 2009 – 2011
Currently in post-injection
monitoring
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 7
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
8. MT CCS II Project Overview
Purpose: Advance the development of the Alstom Chilled Ammonia
Process (CAP) CO2 Capture technology and demonstrate CO2 storage
and monitoring technology at commercial scale
Project Participants
AEP, USDOE, Alstom, Battelle, WorleyParsons, Potomac Hudson, Geologic
Experts Advisory Team
Location: Mountaineer Power Plant and other AEP owned properties
near New Haven, WV
Preliminary cost estimate: $668 million
50/50 DOE cost share up to $334M
Project Technical Objectives
90% CO2 removal from the stack gas
Store 1.5 million metric tons of CO2/year
Demonstrate commercial scale technology
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 8
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
9. Chilled Ammonia Process Overview
Gas to CO2
Chilled Stack
Water Reagent
CO2
CO2
Flue Gas Gas
Cooling Cooled CO2 CO2 CO2
from FGD Flue Gas Absorber Regenerator
and
Cleaning Clean
CO2 to
Storage
Reagent Heat and
Pressure
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 9
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
10. FEED
Technical Objectives
Conceptual Design Basis Complete
Complete technical studies and investigations related to
Establishing process design parameters
Balance of Plant (BOP) systems integration
Location/Arrangement of equipment
Environmental Impact Statement (to satisfy NEPA)
Engineering and design documents to support cost +/-
25% cost estimate
Engineering in position to freeze design early in Detailed
Engineering phase.
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 10
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
11. MT CCS II
Summary of FEED Activities
Process Design w/ Alstom & WorleyParsons
Site Design Conditions and Criteria (AEP)
Weather Data (temps, rainfall, wind rose)
Site Characteristics (location, elevation, seismic criteria, etc.)
Available Water & Utilities Info
AEP Design Criteria (by discipline)
Applicable codes & standards
Periodic site walk-downs
Equipment locations
Steam and other BOP tie-ins
Integrated E&D workshops (CAP and BOP)
Wiesbaden, Germany
Knoxville, TN
Reading, PA
Columbus, OH
CAP/BOP Design Basis, M&E Balances and Process Flow
Diagrams
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 11
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
12. MT CCS II
Summary of FEED Activities
Process Hazards Analysis
Utilized WorleyParsons’ HAZID Process
Team Meeting at WorleyParsons in Reading, PA
Identified potential process and logistical hazards & risks
Precursor to a formal HAZOP (Phase II)
Used in Phase I to identify focal points for detailed
engineering/design
Constructability Reviews
Participation from AEP Construction, WorleyParsons and Alstom
Modularization
Equipment Delivery (i.e. Barge Unloading)
Construction-related risks
Weather
Labor
Assembly logistics and crane utilization
Materials of construction (alloys, vessel packing etc.)
3D Model / Accessibility Reviews (Monthly)
Used to determine maintenance access, egress, walk-ability.
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 12
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
13. Summary of
FEED Deliverables (Capture)
Process Flow Diagrams (PFDs)
Material and Energy Balances
Summer (full load)
Average Ambient (full load)
Low Ambient
Part Load
General Arrangements (GAs)
Process & Instrumentation Diagrams (P&IDs)
Electrical One-Line Drawings
System Descriptions (Control Philosophy)
3D Model (included piping 2.5 inches and larger)
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 13
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
14. Key Studies & Investigations
Steam Supply to CAP
Based on steam cycle evaluation and process
optimization, the conceptual design basis would be to
extract steam at two different pressure levels:
higher pressure steam for regeneration from the IP/LP
crossover utilizing throttling valves (butterfly type)
Lower pressure to supply steam for process stripping.
Condensate Return from CAP
returned to the Mountaineer feed water heating system to
reclaim the condensate as well as offset a portion of the
overall energy demand.
To minimize contamination concerns, a condensate storage
“buffer” tank is included in the design, which is continuously
monitored for contamination.
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 14
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
15. Key Studies & Investigations
CAP Reagent Study
Anhydrous ammonia selected:
optimum reagent to maintain/control ammonia molarity in the
CAP and to recover from molarity upsets during process upsets,
load fluctuations and maintenance activities
least risk of impurity addition, which can cause process upsets,
and effluent for streams requiring additional treatment.
lowest capital and operating cost of the reagents compared
CAP Refrigerant Study
Ammonia offers the lowest energy consumption (highest
efficiency) and the lowest installed capital cost, with minimal
environmental impact with respect to ozone depletion,
greenhouse effect, or global warming.
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 15
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
16. Key Studies & Investigations
Chilled Ammonia Process Byproduct Handling
Focused on beneficial use and disposal options
Recovery of Crystallized Ammonium Sulfate for Resale
Recovery of 40 wt% Ammonium Sulfate for Resale
Alternate process to react ammonium sulfate with lime to recover
ammonia and produce gypsum that could be combined with
Mountaineer’s gypsum waste product from the FGD.
40 wt% solution selected as design basis
Lower energy demand
Optimal product for end-user
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 16
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
17. Key Studies & Investigations
CO2 Compression
Maximum injection pressure into the geological
formations targeted for the project is expected to be
approximately 3000 psi (207 bar).
Injection pressures in the 1200 psi – 1500 psi (83 –
103 bar) range are expected early in the life of the
target injection wells (from PVF operating experience).
Compression to an intermediate pressure, followed by
variable speed pumping to the final injection pressure
offers greater flexibility and efficiency over the life of
the system as compared to full compression to the
maximum expected injection pressure.
Integrally geared technology is proven, cost effective, and
offers, with the use of a variable-speed drive on the CO2
pump, a wide range of outlet pressures.
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 17
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
18. Key Studies & Investigations
CCS Control Systems
All control and monitoring associated with process
systems and equipment will generally be from the
Distributed Control System (DCS) terminal located in a
dedicated CCS control room located near the CAP.
CCS Control Room Features
Designed as a continuously occupied control center
designed to accommodate two (2) operators and a shift
supervisor.
Included all the necessary displays for safe operation of
both the capture and storage systems.
Normal control and monitoring will be from the DCS
Operator Interface Terminal (OIT)
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 18
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
19. FEED Conclusion
FEED conceptual design basis was sound and poised for
kickoff of detailed engineering and design.
CAP design will meet stated objectives
Scope of integration is practical and achievable
Parasitic load estimates are accurate and realistic
Design basis more than adequately supports a +/- 25% cost
estimate
Opportunities for improvement exist and could be realized in the
detailed design phase
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 19
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
20. Key Technical Takeaways
Overall the conceptual design and integration of the CAP and its
associated BOP systems into the Mountaineer power generating station
was a success.
Keep integration expectations practical.
Collaborative process was instrumental in identifying many of the
technical risk factors up front.
Keep plant personnel involved and informed
Selection of process steam source that minimized extraction ties,
eliminated significant turbine modifications, and kept the operation of the
steam supply as simple as practical.
Based on experience with injection at Mountaineer, pressures below 3000
psig (207 bar) were likely to be sufficient to inject CO2 into the targeted
underground reservoirs
Reduced overall energy demand due to lower pressure
Compression to an intermediate pressure, followed by variable speed pumping
offers greater flexibility and efficiency
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 20
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
21. Estimate Approach
Approach:
Front end engineering & design supports a target +/- 25% cost estimate
Major equipment costs are based on budgetary quotes
Estimated quantities for capture system are based on 3-D model
Labor costs for capture are based on quantities and Worley Parson’s data base
Estimate aligns with contracting strategy
Escalation is applied with respect to the project execution schedule
Process and Tools:
Collaborative team effort involving Alstom, WorleyParsons, Battelle, and AEP engineering
and construction inputs
Utilized detailed work breakdown structure (WBS)
Applied lessons learned from Product Validation Facility
Advanced estimate risk modeling techniques per latest industry standard
Collective project team review of estimate (i.e. Red Team Review)
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22. Injection & Monitoring System
Types of Wells Number
Injection 2
Deep Monitoring 9
Intermediate 4
Monitoring
Characterization 1
• Yellow circle shows the extent of the
modeled CO2 plume for 5 year injection.
• The green triangle represents injection
well (1 at each site)
• The red triangle represents monitoring
well
• Yellow and black triangle represents
intermediate monitoring well
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23. Drilling of BA-02 Characterization Well
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24. Logging and Coring: BA-02
Core sample showing connected vugs; refer to CCS Storage Report
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25. Project Cost Estimate (USD)
System (Phases I, II & III) Estimate ($ x million)
Capture
Storage
Subtotal (Overnight Cost) $825
Escalation $71
Subtotal (As Spent) $896
Risk Based Contingency $103
Total Constructed Cost $999
Phase IV Operations $66
Total Project Cost $1,065
Bottoms-up estimate based on approx. 10 - 15% engineering and use of 3D model.
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its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 25
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
26. Major Risks & Opportunities
Risks Opportunities
Escalation Initial Overdesign
Wide ranging scenarios Address in detailed
Underground Injection Control engineering
Permit Modularization
Application first Apply AEP Experience
Scope of Storage Well System Installed spares
Additional wells RAM study would confirm
Craft Labor extent
Schedule built with 5 – 8s and Structural Steel
5% casual overtime Mostly in absorber building
Scale-up area
Unknown but expected
issues post design freeze
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its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 26
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27. Risk Modeling
Relative Ranking of Risks Probability of under run
Risk modeling provides a total cost estimate (Phases I – IV) ranging from $962-million to $1.065-billion
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 24
errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.
28. In Summary
The work completed in Phase I continues to support the
commercial readiness of Alstom’s CAP technology at the
intended scale and provides AEP and DOE with a good
understanding of the project’s risks, capital cost, and
expected operations and maintenance costs during planned
Phase IV operations.
The completed front-end engineering and design package
provides a sound basis for completion of the project when
conditions warrant the continuation of this or a similar
project elsewhere in the U.S.
More about AEP at <www.AEP.com>
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information contained therein. Use of the report and the information found therein is at the sole risk of the recipient. American Electric Power Company,
its affiliates and subsidiaries, shall not be liable in any way for the accuracy of any information contained in the report, including but not limited to, any 28
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29. Q&A
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errors or omissions in any information content; or for any loss or damage of any kind incurred as the result of the use of any of the information.