Imperial College carbon capture pilot plant Preparing today s students for tomorrow s world

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1 Imperia Coege carbon capture piot pant Preparing today s students for tomorrow s word

2 Panting the seeds of change today Shaping tomorrow s engineers By suppying equipment for Imperia Coege s carbon capture piot pant, ABB aims to equip today s students with the skis needed to run tomorrow s industria processes. The ony faciity of its kind in an academic institution in the word, the piot pant shows students how the atest technoogies can hep to optimise pant performance and safey manage emergency situations in rea-ife appications. The opportunities for ABB and Imperia are immense. The faciity provides a once in a ifetime opportunity to infuence the training and education of thousands of young chemica engineers over the next 20 years at one of the word s premier chemica engineering departments. The agreement between ABB and Imperia Coege gives the university access to the most advanced contro and instrumentation technoogy avaiabe from any manufacturer, as we as ife cyce services and support for the instaation. In return, ABB has access to the carbon capture piot pant for its own use and wi use the faciity for customer demonstrations and training, staff earning such as inter-divisiona training and hands on experience for its apprentices and graduate engineers. ABB wi be abe to tria new technoogy in a ow risk, wemanaged environment to gather Beta site test data. Quite simpy, there are very few industria companies that have utiised a the eading-edge technoogy that Imperia is featuring within this piot pant. With many internationa students aso studying at Imperia, the faciity wi hep to position the UK as one of the goba centres of exceence and expertise for engineering education. For ABB, there is the added attraction of buiding awareness of its technoogies and capabiities across a goba audience. The increasingy goba nature of the projects that ABB are invoved with, particuary in the oi, gas and petrochemica sectors, means that engineers from the UK and esewhere are being caed on to work in many different regions wordwide. The aim is to use the pant to create a asting association between the rea-ife probems that students wi encounter once they quaify and the technoogy and capabiities avaiabe from ABB that can hep sove them. 2 Panting the seeds of change today Imperia Coege carbon capture piot pant

3 Lessons in the power of integration A joined-up approach to teaching Bringing industry into the cassroom The carbon capture piot pant is part of Imperia Coege s 8.9 miion ChemEngSpace Project and wi be used for undergraduate teaching, with over 300 chemica engineering students having access each year. The CO 2 piot-scae absorption pant uses an extensive seection of the same ABB proven products and systems that are used in a broad range of industria appications wordwide. The pant is designed so that students get hands-on experience of ABB s product and system integration by showing them in action in a cutting-edge industria appication. By using this equipment, students can gain vauabe practica experience of pant operation that wi hep prepare them for the industria chaenges of tomorrow. Together, ABB s contro systems, process instrumentation, variabe-speed drives, motors and eectrica contros, give operators everything they need to run their pant efficienty, safey and with minimum environmenta impact. ABB has provided a wide variety of products for use in the pant, incuding: System 800xA distributed contro system 800HI SIL3 integrated safety contro system Extended operator workpace (EOW) Pressure and differentia pressure transmitters Temperature sensors and transmitters Eectromagnetic fowmeters Swir and vortex fowmeters Variabe area fowmeters Coriois mass fowmeters Differentia pressure (DP) fowmeters Leve measurement ph anaysers CO 2 gas anayser Smart vave positioners Paperess data recorders Low votage AC drives and motors Low votage eectrica products Lessons in the power of integration Imperia Coege carbon capture piot pant 3

4 Imperia Coege carbon capture piot pant How the process works Finding ways to mitigate the effects of industria activity on the environment is assuming ever greater importance in the fight against cimate change. With CO 2 from industry and power generation contributing to rising goba temperatures, new ways need to be found to hep reduce the quantities of CO 2 being emitted to atmosphere. 6 As a means of capturing and ocking away CO 2, carbon capture and storage is increasingy being seen as a viabe way of tacking the probem. Step1 Carbon dioxide (CO 2 ) and nitrogen enter the system (1). The gas mixture is passed into a saturation vesse (2), so that the CO 2 becomes saturated with water before passing into the absorber tower. This heps with the subsequent CO 2 absorption process. Step 2 The gas rises up the absorber tower (3) as the mono-ethano amine (MEA) soution fows down from the top. The CO 2 absorption process requires specific pressure, temperature and ph conditions. 4 Step 3 The CO 2 -rich amine soution is pumped to the top of the regenerator tower (4). It then fows into the re-boier (5) by natura convection processes, where the iquid is heated and a fraction turns into vapour. Step 4 The vapour passes up the regenerator tower into the condenser (6) where the amine soution condenses, eaving the CO 2 as a gas to be coected. The CO 2 -free iquid MEA returns to the regenerator and is then pumped back to the top of the absorber tower (3). 5 4 How the process works Imperia Coege carbon capture piot pant

5 The pant uses over 250 instruments, measuring parameters incuding temperature, pressure, ph, eve, carbon dioxide and fow. 3 The pant has a capacity for 50 kg per hour capture of carbon dioxide. 2 1 The construction of the pant is part of Imperia Coege s 8.9 miion ChemEngSpace project. How the process works Imperia Coege carbon capture piot pant 5

6 The ABB Contro Room Main features A information from the process is reayed to the ABB Contro Room, from where students can monitor and contro every aspect of the pant. Over 250 separate process instruments provide rea-time feedback on fow, temperature, pressure, eve, ph and CO 2 eves. This data is fed to the contro system via severa different communication protocos, incuding Foundation Fiedbus, Profibus DP, Profibus PA and Wireess HART, where it is then shown as part of the rea-time process dispay on dua extended operator workpaces. Using the atest ipad technoogy, the pant operators can aso remotey monitor the process whist working outside of the ABB Contro Room. Ergonomicay designed operator interface Information from the pant is reayed to the operators via the various dispay screens. Updated with rea-time data, these screens provide a comprehensive picture of a aspects of the pant s operation. Getting the data to the contro room The rea-time data from the pant room is reayed to the contro room via ABB s AC800M contro technoogy. The AC800M integrates various networks, fiedbuses, seria protocos and I/O ready for presentation to the System 800xA as we as hande the rea-time contro of the pant. 6 The ABB contro room Imperia Coege carbon capture piot pant

7 Advanced contro and instrumentation technoogies Harnessing the word s most advanced designs Powering instruments using energy harvesting Energy harvesting provides new and cost effective options for powering wireess instruments. The cost and power chaenges of networking instruments Wireess instruments offer the idea soution wherever it may be costy or impractica to run cabing. Battery-powered WireessHART technoogy aows for quick and simpe instrument instaation to aow operators to monitor new process information to improve pant visibiity. However, the battery wi eventuay need repacing, incurring time and cost. Battery ife can be proonged but ony by sowing down the data transfer rate, affecting the instrument s response time. The soution is to use remote instruments powered by energy harvesting technoogy The Imperia Coege piot pant features ABB temperature transmitters fitted with ABB s FiedKey WireessHART adapters and another transmitter using an integra therma gradient energy harvester. The FiedKey adapter is for appications where there is oca power avaiabe but no signa cabe back to the contro room. It harvests energy from the 4-20mA oop and adds WireessHART connectivity to any HART instrument. At Imperia Coege, temperature instruments with FiedKey adapters are instaed on a coumn, reaying process data back to the contro room via WireessHART. The temperature instrument using therma gradient energy harvesting is fitted to a steam pipe where the temperature difference from ambient to that of the steam pipe is used to power the instrument. A battery is incuded for situations where there is no steam fowing. Normay, the battery shoud never require repacement unti its 20 year shef ife expires. Obtaining rea-time information on pant performance In any industria process, having quick access to reatime pant data can have a significant impact not ony on performance but aso other critica areas, incuding safety. The chaenges of a non-integrated contro system Probems arise where process data is presented in mutipe formats on mutipe patforms (automation, eectrica and teecoms). Lack of integration in a contro system can mean that operators may have no way of pinpointing issues or quicky driing down into process data or maintenance records, for exampe. This can have a significant impact on process performance and operator efficiency and can cause deays in responding to emergency situations. The soution is ABB s System 800xA distributed contro system ABB s System 800xA is a scaabe extended automation system for contro and monitoring, instrumentation, eectrica integration, safety and maintenance for process industries. Capabe of being integrated with ABB and third party equipment, System 800xA provides operators with a singe, consistent environment for managing their compete process. At the heart of System 800xA is ABB s Aspect Object technoogy. This reates a pant data identified as Aspects, to specific pant assets, referred to as Objects. Operators can cick on any of the pant assets to access rea-time data for monitoring or controing the pant independent of the type of automation or eectrica device providing the contro function. In common with rea-ife instaations wordwide, the System 800xA in the ABB Contro Room at Imperia Coege enabes students to contro a aspects of pant operation, incuding data monitoring and coection, engineering configuration, maintenance and safety routines such as emergency shutdowns. Harnessing the word s most advanced designs Imperia Coege carbon capture piot pant 7

8 Designed with education in mind Putting the practice behind the theory Teaching mutipe fow techniques The piot pant uses many different fow technoogies to demonstrate the various options for industria appications. The chaenge of fowmeter seection Engineers are faced with a wide choice of fow technoogies, each offering distinct advantages and drawbacks. As every type of iquid or gas behaves differenty as it fows through a pipeine, it is important to choose the fow technoogy that can guarantee the best accuracy. The soution fowmeters in series Imperia s piot pant features three points where different fowmeters are instaed in series. Steam fow to the piot pant is measured by both an ABB OriMaster M fowmeter and an ABB Swir meter. The OriMaster M is a differentia pressure fowmeter, which measures directy in mass or corrected voume units. It incorporates a of the major components needed for an orifice pate instaation into a singe assemby, significanty reducing instaation costs. The Swir meter measures the fow rate based on the frequency of pressure variations formed as steam, gas or fuids meet a fixed spira obstruction inside the meter body. In comparison to the OriMaster, the Swir meter requires itte straight pipe upstream to get the best accuracy, making it idea for compact instaations. On the amine chemica feed ine to the regenerator coumn, two ABB meters are used to compare eectromagnetic fow measurement against the swir measurement technique. Comparing communications protocos To enabe the process to be managed from the contro room, a equipment on the piot pant is inked via various forms of communication to the System 800xA contro system. The Imperia Coege instaation features exampes of a of the eading types of pant-wide communications technoogies, enabing students to compare and evauate each one in an actua operationa setting. The chaenges of pant-wide communications Disagreement over a common standard has meant there are many different fiedbus protocos for use in industria appications. With each type of fiedbus offering its own merits, it is important to be abe to understand what needs to be considered when making a choice and the factors that can affect operation. These factors can incude data propagation time, suitabiity for use in hazardous areas, power requirements and abiity to integrate with other systems. The soution teaching mutipe protocos In a rea-ife appication, the choice of communications protoco is ikey to depend on a variety of factors, incuding the age of the pant and the required speed of response between the device and the contro system. In contrast to rea-ife industria sites, which are ikey to standardise on just one protoco, the Imperia Coege piot pant utiises a combination of Profibus PA, Profibus DP, Foundation Fiedbus (HSE and H1), HART, Ethernet and WireessHART technoogies. On the nitrogen gas ine the pant utiises a Vortex fowmeter in series with a therma mass fowmeter. Another exampe of two totay different technoogies operating on the same process media. 8 Designed with education in mind Imperia Coege carbon capture piot pant

9 The pant that adapts to changing conditions Teaching practica skis Controing the carbon separation process Imperia s piot pant wi be used to run hundreds of different scenarios and experiments in coming years, caing for a highy adaptive set-up which can be readiy adjusted to produce the conditions needed. This adaptabiity is we met by ABB s System 800xA integrated automation soution. The chaenge of maximising carbon separation efficiency The piot pant uses a chemica sovent of mono-ethano amine (MEA) chemica to first absorb and then assist in the separating out of the carbon dioxide (CO 2 ). For maximum process efficiency, the absorber and regenerator towers have to be maintained at steady temperatures of 45 C ±2 C and 115 C ±2 C respectivey. The fow rate of the MEA to the absorber tower aso needs to be carefuy controed in order to contro the rate of CO 2 absorption. The soution integrated process contro With a pant equipment being connected to the System 800xA contro system, operators are abe to easiy adjust device settings to experiment with different scenarios. This can be achieved simpy by cicking on the icons representing those devices. Adjusting the desired set-point vaue on the process steam suppy, for exampe, wi enabe the operator to either increase or decrease the process temperature, which can affect the abiity of the MEA to absorb CO 2 via the reevant contro vave. Simiary, the pant operator can vary the feed rate of the MEA by changing the set-point of the fow contro oop that utiises variabe-speed drives on the MEA feed ine. In this way students can appreciate the different technoogies used in fow contro. The increase or reduction in the fow rate wi be detected by the fowmeters on the ine, with the data being reayed to the System 800xA to hep contro the variabespeed drives. Aarms and event management for a safe future Subject to the same stringent safety requirements as any rea-ife industria process, the Imperia Coege piot pant features a comprehensive range of safety measures designed to immediatey aert operators to out-of-range or emergency situations. The chaenges of handing emergency situations Even in a fuy automated contro room, a human presence is sti needed to ensure that emergency situations are handed quicky and efficienty. This can often be difficut in traditiona contro room situations, where messages may be reayed to separate systems and dispayed in different formats. This can cause a deay in tracing the root of a probem, during which time the potentia consequences may escaate. The soution integrated aarm management The TÜV-safety certified System 800xA at Imperia Coege has specific aarms incuded for: Asphyxiation caused by eaking CO 2 or nitrogen gases Dangerousy high or ow eves in the stripper and scrubber coumns Excessive pressures in the coumns Overheating of heaters, cooers and the stripper and scrubber coumns To hep operators to quicky address a probem, the System 800xA incudes visua and audio aarms, CCTV cameras that focus on probem areas via the EOW and faciities to raise and ower the desk to enabe the operator to hande a situation whist standing or sitting. Automatic shutdown routines are triggered in the event of a safety aarm not being acted upon. A major events within the pant are recorded, producing historica data that can be examined to trace the conditions eading up to the aarm situation. In this way students can work to, and understand, the atest internationa best practice. The pant that adapts to changing conditions Imperia Coege carbon capture piot pant 9

10 Overview of ABB equipment suppied How ABB s equipment is used in the pant The Imperia Coege piot pant uses over 250 ABB instruments to provide rea time feedback to the ABB Contro Room. Each instrument is connected using a variety of communications protocos. Did you know? The ABB equipment suppied is backed up by a 10 year agreement to provide ifecyce services and support for the instaation. Pant components Pressure Temperature Actuators Fow measurement Recorders Anaytica Anaytica Drives Motors Controers and I/Os and and (Water) (Gas) Positioners Controers Measurement type 266 transmitter 268 transmitter 364 transmitter Pressure gauge Temperature sensors TSP3xx Temperature transmitter TTF3xx TZID inear positioner + EDP300 positioner OriMaster M OriMaster V Swir Vortex Coriois Variabe Area (Meta) Variabe Area (Gass) Eectromagnetic Therma mass SM500F paperess recorder SM3000 paperess recorder AX400 (ph) EL3020 (Cados 27) ACS880 Low votage motors 800M controer 800HI controer I/O units Safety I/O units Absorber coumn Stripper coumn CO 2 ine Lean MEA ine Cooing system Gas circuation and recycing Heat exchanger Heaters Liquid from condenser to cooer Liquid from cooer to separator Pumping system Rich MEA ine Steam system Fiter (Differentia Pressure) Make up water from pump to cooer, deionised + saturated CO 2 Condenser water feed fow contro 10 Overview of ABB equipment suppied Imperia Coege carbon capture piot pant Overview of ABB equipment suppied Imperia Coege carbon capture piot pant 11

11 Contact us ABB Limited Howard Road St. Neots Cambridgeshire PE19 8EU Te: +44 (0) Fax: +44 (0) Notes: We reserve the right to make technica changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particuars sha prevai. ABB does not accept any responsibiity whatsoever for potentia errors or possibe ack of information in this document. We reserve a rights in this document and in the subject matter and iustrations contained therein. Any reproduction, discosure to third parties or utiization of its contents in whoe or in parts is forbidden without prior written consent of ABB. Imperia Coege carbon capture piot pant/apri 2012/250 Copyright 2012 ABB A rights reserved Printed in UK ( )