The document outlines 5 steps to develop a cost baseline for a commercial-scale amine-based carbon capture process at a 555 MWe natural gas power plant. The steps include: (1) developing and validating an Aspen Plus process model, (2) simulating the full plant design, (3) sizing major equipment, (4) estimating capital and operating costs using Aspen Capital Cost Estimator, and (5) analyzing costs and comparing to industry benchmarks. The analysis estimated a total capital cost of $326.6 million and annual operating cost of $47 million for the reference case of a 30 wt% MEA solvent system capturing 1.475 million tons per year of CO2.
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5 Steps to Achieve More CostEffective Aminebased Carbon Capture Processes at Commercial Scale41323.pdf
1. 5 Steps to Achieve More Cost-Effective
Amine-based Carbon Capture
Processes at Commercial Scale
Koteswara Putta, CO2 Capture Technologist, TCM
Gerardo Muñoz, Solutions Mkt Manager, AspenTech
Lee Nichols, VP, Content/Editor in Chief, HP
8. Koteswara Rao Putta
Development of CO2 capture process cost baseline for
555 MWe NGCC power plant using standard MEA Solution
9. Contents:
• Introduction
• Objectives
• Methodology/Steps
• Step 1 : Process Model development and Validation
• Step 2 : Plant simulation
• Step 3 : Sizing of equipment
• Step 4 : Cost estimation
• Step 5 : Economic analysis and results
• Conclusions
10. The world largest open access test centre for carbon capture technologies
Generic Amine Plant Emerging technologies Chilled Ammonia Plant
11. Introduction
Carbon capture, utilization and storage (CCUS) is essential to achieve Net-zero
emissions targets
Increased interest in Post-combustion CO2 capture projects
UK Clusters
Dutch
Norway
Other EU countries
USA
Need for Open-source CO2 capture technology project costs
12. Objectives
Develop Technoeconomic Analysis (TEA) for CO2 Capture Technology with MEA Solvent
Follow Systematic Methodology
Use TCM experience and expertise
CASE STUDY
NGCC Power Plant : 555 MWe
Solvent: 30 wt% MEA (Open-source)
4 vol% CO2
1.475 Million tons/year (@90% capture)
NETL Baseline study (2010)
13. Methodology/Steps
Step 1 : Process Model development and Validation
Step 2 : Plant simulation
Step 3 : Sizing of equipment
Step 4 : Cost estimation
Step 5 : Economic analysis and results
14. Step 1 : Process Model development and Validation
Accurate model is necessary for any amine-based technology full scale plant design
15. Process Model development
The TCM thermodynamic model is based on ENRTL-RK method
Liquid phase - Electrolyte NRTL (ENRTL)
User FORTRAN models
Gas phase - Redlich-Kwong (RK)
Rate Based Modelling approach
Columns
Absorber
Stripper
Water wash sections
Aspen Plus
16. Process Model Validation
Model validation with TCM testing operational data
Tests with reconciled mass and energy balance are selected - criteria:
Overall plant mass balance is 100 +/- 2%
CO2 mass balance 98 +/- 2%
Stable operation at least 2 – 6 hours (steady state operation)
Availability of liquid analysis results for CO2 and amine samples
The Model replicates TCM Amine plant process configurations:
Different absorption packing heights
Water Wash system including coolers
Rich Lean heat exchanger
CHP and RFCC stripper and associated reboilers
Lean Vapor Compressor (LVC) system
Rich Lean bypass
17. Process Model Validation
Operation parameter units Range
Flue gas flowrate sm3/hr 34,000 – 68,000
Flue gas CO2
concentration
vol % 3.6 – 14
Flue gas temperature oC 28 – 45
MEA concentration wt % 28 – 40
Lean amine loading mol/mol 0.1 – 0.3
Lean amine temperature oC 35 – 50
CO2 capture rate % 70 – 99
Absorber packing height m 12,18, 24
Water wash sections # sections 1, 2
Stripper in operation CHP, RFCC
Rich amine bypass % 0 – 20
Operation data window
** Higher deviation in SRD is believed to be caused due to mal-distribution
and foaming in the stripper.
19. Step 2 : Plant Simulation
Plant details
555 MWe NGCC Power Plant - 1.475 Million tons/year
30 wt% MEA (Open-source) solvent
4 vol% CO2
90% Capture
NETL baseline study case 14
Name Value Units
Flow rate 113,831
(3,230,636)
kgmol/hr (kg/hr)
T 143 °C
P 0.1 MPa, abs
Annual operation 8000 hours
Capture rate 90 %
Annual CO2 capture 1,475, 200 ton/year
Composition Mole fraction
Ar 0.0089
CO2 0.0404
H2O 0.0867
N2 0.7432
O2 0.1209
NOX 155 ton/year
Validated Process Model is used for the plant
simulation
20. Step 2 : Plant Simulation
Flue gas Flue gas
conditioning
CW Chemicals
Excess water
CO2 Capture
Unit
Flue gas
Depleted Flue gas to stack
MEA Solvent CW
Solvent
Reclaiming
Steam
CO2 Product
Steam
Chemicals
Condensate
Condensate
Waste
Degraded Solvent
Reclaimed Solvent
21. Step 2 : Plant Simulation
DCC
DCCPUMP
B2
DCCHEX
BLWR
M UL T
B1
143
FGFROMGT
28
S33
52
S34
18
S35
52
S1
52
BLD
52
S3
18
S4
16
DCCSW1
26
DCCSW1R
41
FGTOABS
FGTOABS(OUT)
41
S2
Temperature (C)
Flue gas pre-conditioning implementation in Aspen Plus
23. Step 2 : Plant Simulation
Thermal reclaiming unit (TRU) process flow sheet and implementation in Aspen Plus
Solvent degradation due to impurities in flue gas
Solvent management is key for reliable operation
and plant life
Corrosion, erosion & HSE
Control OPEX
25. Perform sizing of all essential equipment
Columns
Plate heat exchangers
Reboiler
Separators/vessels
Filtration unit
Storage tanks
Cooling towers
Chemical Dosing unit
Reclaimer
Step 3 : Sizing of Equipment
Aspen Plus rate-based model
Exchanger Design and Rating
(EDR)/Vendors
Aspen Plus Sizing/API 12J
TCM design tool
TCM internal data
TCM excel calculation
Domain experts – Standard modules
Domain expertise and TCM calculation
26. E.g. Sizing of Plate Heat Exchangers
Exchanger Design and Rating tool (EDR)
EDR Offers multiple options to define the Plate
Exchanger.
Among the results we can expect diagrams and API
Data Sheets with the size results.
The sizes are used to define sizes in the economic
evaluation tool for more accurate estimation.
29. Step 4 : Cost estimation
The equipment list in Aspen Capital Cost Estimator (ACCE)
Sizes for the equipment are calculated based on the heat and material
balance results form the simulator.
Materials of construction will be key for a correct estimate
Estimate Scope is expanded by ACCE’s Volumetric Model
Approach that includes
instrumentation,
civil,
insulation,
piping based on internal P&IDs
Additional items must be added to finalize TIC scope
Piping Rack structures, interconnecting piping lines,
additional electrical cable runs and utility systems
TIC: Total Installed Cost
33. Step 5 : Economic analysis and results
• After finishing adding all equipment,
raw materials, plant utilities, bulks in
ACCE
– Evaluate the project to generate costing
report
– Capital cost summary with various details is
generated
Capital costs summary from ACCE report
34. Step 5 : Economic analysis and results
Name TCM NETL
Cost base 2019 Q1 2007 June
Capital costs excluding
flue-gas pre-conditioning
(direct), MUSD
172.8 140.0
Prorated costs to TCM
base year, MUSD
- 162.1
Difference (%) - 6.5
TCM Aspen and NETL baseline cost estimates comparison
Name TCM
COST BASIS YEAR 2019 Q1
CAPITAL COSTS, MUSD 326.6
OPEX, MUSD 47.0
35. Step 5 : Economic analysis and results
Total Direct Field Costs
64%
Indirect Field Costs
13%
Total Non-Field Costs
23%
CAPITAL COSTS
(2)
Equipme
nt
(3) Piping (4) Civil (5) Steel
(6)
Instrume
nts
(7)
Electrical
(8)
Insulation
(9) Paint
Labor Cost 1,620,028 17,631,33 2,294,330 203,799 1,918,917 3,251,611 2,287,224 185,445
Matl Cost 103,389,8 47,459,70 2,510,592 1,008,001 16,605,91 7,803,240 2,022,708 123,358
0
20,000,000
40,000,000
60,000,000
80,000,000
100,000,000
120,000,000
Direct Field Costs
36. Step 5 : Economic analysis and results
Summary of equipment material costs
37. Step 5 : Economic analysis and results
Solvent cost VS Annual makeup costs Solvent cost VS Cost of CO2 capture/ton
6.4 % increase
5 % increase
38. Conclusions
An extensive study has been conducted by Technology Centre Mongstad together with
AspenTech to develop CO2 capture process cost baseline
Systematic methodology/steps for reliable cost estimation of CO2 capture projects
Technical expertise and experience is essential
Estimates can provide reliable budgetary quotes for CO2 capture projects