KCP-EEN-CPD-DPR-0001

Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 1 of 9

CO2 Compression and Pumping Philosophy

Table of Contents

1. Scope and Functional Requirements

2. Assumptions
3. Design Requirements
4. Mandatory References
5. Supporting References

Kingsnorth CCS De monstration Pro ject

The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 2 of 9

1. Scope and Functional Requirements

This design philosophy specifies the compression requirements to
transport the CO2 captured at the post combustion capture
demonstration plant at Kingsnorth to the depleted gas field at
Hewett for permanent storage. The compression system will
include a dehydration unit for reducing the water content of CO2 to
make it suitable for pipeline transportation and injection into the
reservoir.
It has been confirmed by Baker RDS that CO2 will be injected into
the pipeline in the gaseous phase for the duration of the expected
term of the demonstration (i.e. all flow into the pipeline and field
during the term of the DECC demonstration will be conducted with
the captured and transported CO2 flowing in the gaseous phase)
[S1].
Even though dense phase operation will not be required during the
DECC demonstration period, this document also considers the
findings by Genesis Oil & Gas Consultants resulting from their flow
assurance work for dense phase operation.
2. Assumptions
a) The eventual transition from gaseous to dense phase operation
after completion of the DECC demonstration is planned to avoid
two-phase flow conditions either in the pipeline or in the wells.
At present, existing capabilities for dynamic modelling of twophase flow behaviour are not experimentally validated for CO2.
If and when these models are validated and improved, it might
be possible to relax the current assumption and allow two-phase
flow in some sections of the pipeline and/or wells. This could
potentially reduce the compression power and/or the heating
load required to condition the CO2 before transport in the
pipeline and/or before injection into the wells.
b) The compressor upgrade from gaseous to dense phase
operation must be considered, at least conceptually, from the
start of the demonstration project as additional space will need
to be provided in the detailed design in order to accommodate
the new compression stages and associated intercoolers and
other equipment. It is highly desirable to be able to continue to
utilise the remaining life of available equipment installed for
initial gaseous phase operation as part of this upgrade.

Kingsnorth CCS De monstration Pro ject

The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 3 of 9

3. Design Requirements
3.1 Compressor Technology
At present, there is a preference to utilise an integrally geared type
compressor for this application. This type of compressor offers two
main advantages over the single shaft design: (1) it can reduce the
compressor power consumption by intercooling after each
compression stage and (2) its footprint is smaller. In addition, the
integrally geared design has been demonstrated in other CO2
applications (e.g. enhanced oil recovery projects) and the sizes and
technical characteristics required for this project are available from
a variety of compressor suppliers.
Nevertheless, taking into account the recent E.ON announcement
that the Kingsnorth project will be postponed, it is important to
continue to track and consider any alternative compressor (or
pump) type that becomes available in the market or is subject to
operational trials on any similar CO2 service.
3.2 Location of Compression Plant
It has been recommended to locate the compression plant as close
as possible to the strippers in the capture plant to minimise the
pressure drop in the suction pipework and also to reduce the
demand for parasitic compression power.
Safety concerns
regarding the presence of high pressure rotating equipment and
piping containing high pressure CO2 were addressed in HAZID
sessions. While it was recognised that a risk would be present, it
was concluded that appropriate mitigation actions were technically
available and economically feasible. These have been proved
worldwide in other applications handling high pressure CO2 in
compact plant areas such as urea plants, where the compressors
are also located as close as possible to the strippers supplying the
CO2 [S5 to S7].
3.3 Number of Compression Trains
It is currently considered that the minimum number of compressor
trains required is two each rated at 50% of the total flow. This is
the minimum number of compressor trains required to provide
current assumptions of flexibility and reliability for the CCS chain. It
has been determined that the use of two compressor trains rather
than one larger compressor will have minimal impact on the
compressor electricity demand. Also, it is the minimum number of
compressor trains recommended by various compressor suppliers.
Nevertheless, this decision must be revisited during FEED 2 and/or
detailed engineering to incorporate information on reliability,
Kingsnorth CCS De monstration Pro ject
The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 4 of 9

availability and maintainability (RAM), as well as updated

predictions on the operational regime of the full CCS chain.
The need for a spare compressor train on stand-by should also be
evaluated to cope with potential malfunctions of a compressor train.
3.4 Type of Compressor Drive
At present, electric drives are the preferred option. Gas turbines
were discarded as they would produce CO2 that would not be
easily captured. The electric drive is the preferred option as it will
simplify the issues associated with the location of the compression
plant while maintaining the requirements for flexible operation. It
was considered that, for this demonstration project, the steam
turbine option would have added an increased level of complexity
to comply with flexibility requirements without providing an
additional advantage over the electric drive.
3.5 Dehydration Technology
Molecular sieve technology has been selected as the preferred
dehydration technology. Although it is more expensive (both
CAPEX and OPEX) than the alternative triethylene glycol (TEG)
technology, there are major technical concerns with TEG
technology: (1) potential inability to maintain water content in CO2
within specification, (2) emissions of TEG to the atmosphere, (3)
contamination of CO2 with TEG with potential major deleterious
effect on injection of CO2 into the reservoir, (4) inability of TEG to
operate above 40 C (5060 C is the preferred temperature at the
compression plant outlet at the start of injection during the gaseous
flow demonstration phase CO2 into the pipeline), (5) time to settle
out to stable process operation is excessive with TEG and (6)
significant reliability advantages of molecular sieve over TEG [S11
to S12].
3.6 Compression Plant Trips
The compression plant will incorporate control systems to monitor
the water content of the CO2 and the pipeline inlet pressure (outlet
of the compression plant) and to trip the system when these
specifications are not met for a period of time (to be determined in
FEED 2).
3.7 Temperature at Compression Plant Outlet
The temperature of the CO2 stream at the outlet of the
compression plant has been assumed to be 40 C in FEED 1A.
For the time being this will continue to be the design outlet
temperature for the demonstration project. However, E.ON may
seek to increase the outlet temperature to 50 C during the
Kingsnorth CCS De monstration Pro ject
The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 5 of 9

demonstration (gaseous) phase operation. This higher outlet

temperature would, if viable and able to be consented, would
reduce the cooling load in the compression plant.
Calculations of the outlet temperature for dense phase operation
(beyond the scope of the demonstration period) are currently
inconclusive given that the modelling software is unable to
converge at 40 C (convergence has been reached at 30 C only).
However, it is unclear at this stage if this reflects real instability of
flow in the pipeline or if the modelling software itself is unable to
model these conditions accurately [S15].
Finally, higher CO2 stream temperatures (in the range of 5060 C)
will be required to start injecting CO2 into an empty pipeline for a
period of time, after which the operating temperature will be 40 C
under steady-state operation [S12].
3.8 Use of Water Condensed in the Compression Plant
In the compression plant, a continuous stream of water will be
produced after condensation in the compressor intercoolers. This
stream will contain low concentrations of CO2 and amine. It has
been decided that this stream will be sent to the capture plant for
use in the process.
3.9 Water Content Specification for CO2
The water concentration values of 24 ppmv for steady-state
operation and 100 ppmv for short, transient periods have been
agreed by the onshore team (represented by E.ON New Build &
Technology), the pipeline team (represented by Genesis Oil & Gas
Consultants) and the reservoir team (represented by Baker RDS).
The main driver for this decision is to ensure that no free water will
be present at any time in the pipeline, therefore minimising the
opportunity for internal corrosion damage in the pipeline. The
value of 24 ppmv was quoted by Genesis Oil & Gas Consultants in
the pre-FEED phase in 2009 as being a maximum value to avoid
the formation of hydrates in the offshore facilities. This water
content specification is within the limits of other CO2 pipelines in
commercial operation worldwide. This specification could be
revised in the future after consultation with specialist molecular
sieve suppliers.
3.10 Requirement for an Oxygen Removal Unit
An oxygen removal unit located within the compression plant
battery limits will not be required. The pipeline team (supported by
Genesis Oil & Gas Consultants) and the reservoir team (supported
by Baker RDS) have confirmed that the oxygen content of the CO2
Kingsnorth CCS De monstration Pro ject
The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 6 of 9

entering the pipeline (200 ppmv maximum) does not have to be

reduced. It has been found that this value is acceptable and will
not cause oxygen-induced corrosion provided the water content is
limited to 24 ppmv for steady-state operation and 100 ppmv for
short, transient periods. The requirement for an oxygen removal
unit could be revised after consultation with suppliers [S19 to S20].
3.11 Heat Integration
A preliminary heat integration study for the compression plant was
completed in FEED 1A [S21]. This study considered the full
replacement of the sea cooling water used for CO2 compression
intercooling in the base case with power island condensate. This
case completely eliminates the need for sea cooling water to the
CO2 compression and dehydration unit. The recovery of CO2
compressor waste heat for power plant condensate heating slightly
increases the overall plant efficiency. However, the capital cost
arising from the significantly larger heat exchangers is expected to
outweigh the operating cost benefit of the efficiency improvement.
It is therefore only recommended to incorporate this integration
option if the logistical benefit of removing the sea cooling water, as
well as efficiency improvements, are a high priority.
If full integration were adopted, then further work is recommended
in order to determine the optimum condensate return temperature
to balance increased heat exchanger transfer surface area (and
hence exchanger footprint, capital cost and pressure drop) against
increased overall plant efficiency (and hence operating costs).
3.12 Transient Operation
No transient work was carried out in FEED 1A. It is a requirement
that this work is carried out in the next phase of the project.
3.13 Air Compression
At the start of FEED 1A the idea of using the CO2 compressors to
compress air for pipeline commissioning operations was
considered. However, it was later decided that this operation
would be carried out using temporarily hired air compressors [S22].
In addition, the possibility of using the CO2 compressors to pig the
already CO2-filled pipeline using air has also been considered.
This event would only occur in case of a catastrophic failure of an
element of the CCS chain that required emptying the pipeline for
safety reasons. The probability of occurrence of such an event has
been quantified as 1 in 30 years. This requirement for the
compression plant was not evaluated in FEED 1A and therefore will
have to be addressed in the next phase of the project.
Kingsnorth CCS De monstration Pro ject
The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 7 of 9

3.14 CO2 Stream Entering the Compression Plant

The specifications of the CO2 stream entering the compressor plant
are shown in Table 1 [S23 to S25]. These values assume that the
capture plant reduces its load in tandem with a load reduction in
the power plant. The full load data correspond to 6,600 t/d of CO2
captured.
Table 1: CO2 Stream Entering the Compression Plant
Units

100% load

60 % load

25% load

Temperature

35

35

35

Pressure

bara

1.49

1.49

1.49

Molar flow

kmol/h

6490

4334

1906

Mass flow

kg/h

279668

186776

82150

CO2

% mol

96.45

96.45

96.45

H2O

% mol

3.50

3.50

3.50

N2

% mol

< 0.03

< 0.03

< 0.03

O2

% mol

< 0.02

< 0.02

< 0.02

3.15 Gaseous Phase Operation

In their flow assurance work, Genesis Oil & Gas Consultants
reported that the pipeline inlet pressures required for gaseous
phase operation range from 28 bara (start of CO2 injection) to 36
bara (end of CO2 injection in gaseous phase). These values
correspond to the pressure downstream of the landfall valve at the
beach [S15].
In between the compression plant and the landfall valve there will
be a CO2 metering system, an emergency shutdown valve and the
onshore section of the pipeline. Therefore, a provision for the total
pressure drop has been made. In FEED 1A it has been considered
that the pressure at the outlet of the compression plant will range
from 32 bara (start of CO2 injection) to 40 bara (end of CO2
injection in gaseous phase).
3.16 Dense Phase Operation
Dense phase operation will be beyond the DECC demonstration
period. Nevertheless, preliminary flow assurance work was carried
out to evaluate the feasibility of dense phase injection after
completion of the DECC demonstration project. Genesis Oil & Gas
Consultants reported that the pipeline inlet pressure required for
Kingsnorth CCS De monstration Pro ject
The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 8 of 9

dense phase operation is 88 bara. This value corresponds to the

pressure downstream of the landfall valve at the beach [S15].
Given the preliminary nature of this work, it was decided not to add
a provision for the total pressure drop in the section between the
compressor plant and the landfall valve. Instead, the reported
value of 88 bara was used in the calculations in FEED 1A.
4. Mandatory References
[M1]

API Standard 617. Axial and Centrifugal Compressors

and Expander-Compressors for Petroleum, Chemical and
Gas Industry Services

[M2]

API Standard 672. Packaged, Integrally Geared,

Centrifugal Air Compressors for Petroleum, Chemical,
and Gas Industry Services

5. Supporting References
[S1]

KCP-RDS-CWE-REP-1002 Vertical Flow Performance

[S5]

KCP-FSW-PTL-LAY-0001 Plant Layout Drawings

[S6]

KCP-FSW-PTL-ACD-0001
Drawings

[S7]

KCP-FSW-CPD-REP-0001
Compression Plant

HAZID

[S11]

KCP-FSW-CPD-STU-0003
Report

Dehydration

[S12]

KCP-GNS-FAS-DRP-0003 Transient Analysis Start-Up

(Pipeline)

[S15]

KCP-GNS-FAS-DRP-0002
(Pipeline)

[S19]

KCP-FSW-CPD-STU-0001 Oxygen Content Reduction

Study Report

[S20]

KCP-RDS-CWE-REP-1000
Properties

[S21]

KCP-FSW-CPD-STU-0002 Heat Integration Study Report

[S22]

KCP-GNS-PCD-DPR-0011
Commissioning Philosophy

[S23]

KCP-FSW-CPD-PFD-0006 CO2 Compression and

Dehydration Unit 100% Boiler Load Heat and Material
Balance

Building
and

Steady

Establish

Platform

Architectural
ENVID
Unit

State

CO2

and

for

Study

Analysis

Supply

Pipeline

Kingsnorth CCS De monstration Pro ject

The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.

KCP-EEN-CPD-DPR-0001
Rev.: 03
Project Title:

Kingsnorth Carbon Capture & Storage Project

Document Title:

CO2 Compression and Pumping Philosophy

Page 9 of 9

[S24]

KCP-FSW-CPD-PFD-0007 CO2 Compression and

Dehydration Unit 60% Boiler Load Heat and Material
Balance

[S25]

KCP-FSW-CPD-PFD-0008 CO2 Compression and

Dehydration Unit 25% Boiler Load Heat and Material
Balance

Kingsnorth CCS De monstration Pro ject

The information contained in this document (the Infor ma tion) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, e mployees, advise rs, and the Depart ment of Energy and Climate Change
(DECC) make no representation or war ranty as to the accuracy, reliability or co mpleteness of the Infor ma tion and neither E.ON UK
plc nor any of its subcontractors, subsidiaries, affiliates, e mployees, adv isers or DECC shall have any liability whatsoever for any
direct or indirect loss howsoever arising fro m the use of the Infor mation by any party.