MASDAR Process Simulation Verification

Abu Dhabi Carbon Capture and Storage Project- Phase 1 14770-MUS-ESI-PRO-RP-00-0001 Rev C1

TABLE OF CONTENTS

1.0 INTRODUCTION ......................................................................................................... 3

2.0 SCOPE........................................................................................................................ 3

3.0 OBJECTIVE ............................................................................................................... 4

4.0 REFERENCES ............................................................................................................ 4

5.0 METHODOLOGY ADOPTED ..................................................................................... 4

5.1 SIMULATION PROGRAM AND THERMODYNAMIC PACKAGES .............................. 4

6.0 BASIS OF SIMULATION ............................................................................................. 7

7.0 SIMULATION CASES REVIEWED AND CHECKED ................................................... 8

8.0 VERIFICATION OF RESULTS .................................................................................... 9

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1.0 INTRODUCTION

The government of Abu Dhabi launched Masdar in April 2006 to promote advanced
energy and sustainability development in the gulf region. The primary goal of Masdar is
to drive progress to achieve a low carbon economy in Abu Dhabi and the region by
promoting reduction of greenhouse gas emissions through carbon reduction projects and
implementation of environmentally clean technologies.
In June 2007, Masdar initiated the Abu Dhabi Carbon Capture and Storage (CCS)
Project, with the objective to develop an Abu Dhabi based carbon capture network
capable of creating large reductions of CO2 emissions. Phase 1 of the Project aims to
capture approximately 5 million tons per year of CO2 from three facilities in Abu Dhabi.
The captured CO2 is delivered through a new 400km pipeline network to onshore oil
reservoirs to be injected for enhanced oil recovery (EOR) purposes.

ESI Overview

Emirates Steel Industries (ESI) is one of the three industrial plants where Masdar is
planning to install carbon capture facilities as part of Phase 1 of the CCS Project.

ESI is a wholly owned government factory located at Industrial City of Abu Dhabi
(ICAD). It was established in 2001 to satisfy the growing demand for quality steel
products for the UAE, especially deformed reinforcing steel bars (re-bars). The existing
rolling mill in ESI has a design capacity of 600,000 tons of rebar per year.

ESI is currently undertaking major expansion projects in two phases, which will
substantially increase rolling capacity and will establish the factory as a fully integrated
plant instead of a re-roller plant.

Phase 1 expansion includes the installation of a new Direct Reduced Iron (DRI) based
plant and 2 new rolling mills. The DRI plant will have a capacity of 1.6 million tons per
year of direct reduced iron and is scheduled for start-up in June 2009. Phase 2
expansion has similar capacity and is planned for start-up by end 2011.

In this FEED project, the phase 1 expansion plant in ESI is designated as ESI-1 and the
Phase-2 expansion is designated as ESI-2.

ESI-1 and ESI-2 are equally producing 0.4 MMTPA of wet CO2 as a result of the iron
reduction reaction. This produced CO2 is to be incinerated and vented to atmosphere as
per current ESI configuration.

Abu Dhabi CCS Project is planning to install CO2 compression and dehydration facilities
for ESI-1 and ESI-2 to capture 0.8 MMTPA of CO2 and deliver through the CO2 pipeline
network to onshore oil reservoirs for EOR purposes.

2.0 S COP E

The scope of this document is to check, review and verify that the process simulations
are done correctly for the various operating cases for the compression and dehydration
of the Carbon Capture Facilities at ESI.

ESI has two separate steel plants located at a distance of approximately 2 km apart.
CO2 capture and collection facility will be provided for both locations (called ESI-1
and ESI-2). One compression and dehydration train will be provided for each site with
a flexibility to operate into a segregated or load sharing mode. These two trains will

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share a common plot space at the ESNAAD site and share some utilities. ESI-1 is a
distance of approximately 0.7 km and ESI-2 is a distance of 1.2 km from the common
site.

3.0 OBJ ECTIVE

The objective of the CO2 Compression and Dehydration System is to compress low
pressure (0.1 barg) CO2 to pipeline pressure 190 barg and dehydrate the CO2 gas to
acceptable water content for transportation and use in EOR. The utilities will provide
power, water, air, and other utilities necessary for the operation of the CO2
Compression and Dehydration System.

4.0 REFERENCES
The process simulation check is based on the following Process Flow Diagrams.

DOCUMENT NAME DOCUMENT NUMBER

Existing system at ESI plant - Danieli DP017S-FE41-P7000-AD502
Engineering PFD - Stream #3
ESI Process Flow Diagrams 14770-MUS-ESI-PRO-DF-00-4100 through 20-
4183 Rev. B1

The Process Simulation is based on the following documents.

DOCUMENT NAME DOCUMENT NUMBER

Overall Project Design Basis for
Carbon Capture Facilities at ESI
Process Scheme Selection Study
ESI Compression / Dehydration
Study
14770-MUS-GEN-ENG-DB-00-0001
14770-MUS-ESI-PRO-ST-05-0001
14770-MUS-GEN-MEC-ST-05-0001

5.0 METHODOLOGY ADOP TED

5.1 S IMULATION P ROGRAM AND THERMODYNAMIC P ACKAGES

The HYSYS 2006.5 Version simulation software has been used to simulate CO2
compression and dehydration through the entire study. The accuracies of the
simulation results have been evaluated by comparing some of them with the data
published in GPSA (Gas Processors Suppliers Association) Engineering Data
Book (Ref. 5 in Section 6.0).

The default thermodynamic package used in HYSYS is the Peng-Robinson

equation of state property package. The thermodynamic and physical properties
of CO2 calculated by Peng-Robinson method are general good for CO2 and CO2
rich mixtures. However, the saturation H2O content in CO2 calculated by Peng-
Robinson is good for the pressure range below the critical pressure but far off for
the super critical pressure range.

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Since the accuracy of H2O content in high pressure range is very important for
this project, it has been attempted to use different property packages to improve
the accuracy in the high pressure range. Various property packages were tried.
The best results are the ones obtained by the PRSV method. The PRSV model
is a two-fold modification of the Peng-Robinson equation of state that extends to
the application of the original Peng-Robinson method for moderately non-ideal
systems. It performs rigorous 3-phase flash calculations for aqueous systems
containing H2O, CH3OH, or glycols, as well as systems containing other
hydrocarbons or non-hydrocarbons in the second liquid phase.

The test runs showed that the results obtained by PRSV are much better than
those obtained by Peng-Robinson. But the water content calculated by PRSV
are still more than two times higher than the published data when the pressure is
higher than 1500 psia. A trial-and-error method was used to adjust the binary
coefficient of CO2-H2O in the PRSV correlation to match the GPSA data as close
as possible. After the CO2-H2O binary coefficient is changed from the default
value of 0.0445 to 0.2, the calculated H2O contents match the GPSA data very
well for the entire pressure range from sub-critical to super critical.

Some properties calculated by HYSYS using Peng-Robinson and PRSV with

adjusted binary coefficient are compared with the data shown in the GPSA
Engineering Data Book in the following table. The GPSA data are obtained from
the P-H diagram so the readings are only approximate.

Properties GPSA P-R Adjusted PRSV

Density @ 300 psia/40 oF (Vapor),
2.86 2.91 2.91
lb/ft3
Density @ 2000 psia/100 oF (Super
47.6 46.16 46.35
Critical), lb/ft3
Dew Point @ 600 psia, oF 45 44.4 43.1
Heat of Vap. @ 600 psia, Btu/lb 90 90.7 88.5
Critical Pressure, psia 1070 1069 N/A
Critical Temperature, oF 87.76 87.71 N/A

The above table shows that the properties obtained by P-R and the adjusted
PRSV are fairly accurate compared to GPSA data.

The H2O content in CO2 at 100 oF shown in GPSA and calculated by P-R, the
original PRSV, and the adjusted PRSV are compared in the following table and
chart.

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Simulation Results vs. GPSA Data

T = 100 oF
Pressure (psia) 100 200 400 500 750 1000 1200 1500 2000 2500 3000
Sat. H2O Content (lb/MMSCF)
GPSA Data (Fig. 20-9) 490 270 150 130 107 123 150 180 220 227 235
Hysys Using PR 490 272 169 153 144 176 507 1107 1552 1868 2469
Hysys Using PRSV 499 271 163 144 127 140 251 448 573 652 713
Hysys Using Adjusted PRSV 489 261 149 128 105 112 138 188 216 231 242

SAT. H2O IN CO2

3000
H2O Content lb/MMSCF

2500

2000

1500

1000

500

0
0 500 1000 1500 2000 2500 3000 3500
Pressure (psia)

GPSA Data PR PRSV Adusted PRSV

The above chart shows that the H2O content in CO2 calculated by P-R and the
original PRSV are close to the GPSA data for a pressure below 1000 psia.
However, the calculated H2O content are much higher than the published data
when the pressure is above critical. The chart shows that the H2O contents in
CO2 calculated by the adjusted PRSV used in this study match the GPSA data
perfectly for the entire pressure range from 100 psia to 3000 psia.

The comparison of the H2O content calculated by the adjusted PRSV and the
GPSA data at 100 oF is emphasized in the following diagram to demonstrate the
accuracy of the results calculated in this study. The comparison results indicate
that the HYSYS model using the adjusted PRSV used in this study can predict
reliable thermodynamic properties and saturated H2O content.

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Simulation Results vs. GPSA Data

T = 100 oF
Pressure (psia) 200 400 500 750 1000 1200 1500 2000 2500 3000
Sat. H2O Content (lb/MMSCF)
GPSA Data (Fig. 20-9) 270 150 130 107 123 150 180 220 227 235
Hysys Using Adjusted PRSV 261 149 128 105 112 138 188 216 231 242
% Error -3.33 -0.67 -1.54 -1.87 -8.94 -8.00 4.44 -1.82 1.76 2.98

SAT. H2O IN CO2

300

250
H2O Content lb/MMSCF

200

150

100

50

0
0 500 1000 1500 2000 2500 3000 3500
Pressure (psia)

GPSA Data Simulation

6.0 BAS IS OF S IMULATION

The following feed CO2 gas conditions and pipeline gas specifications will be used as the
design basis for the ESI CO2 compression and dehydration facility. Refer to references
listed in Section 4.0 for more detailed project design basis and compressor and
dehydration system design basis.

Feed Gas Composition and Conditions:

(Data obtained from Stream #3 on PFD #DP017S-FE41-P70000-AD502, Sht. 2, Rev. 3)

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Component Mole %
H2 0.21
CO 0.05
CO2 90.21
N2 0.02
H2O 9.43
CH4 0.08
H2S 355 ppm
Total 100.0%

Flow Rate = 25,327 NCMH (22.69 MMSCFD)

Pressure = 0.5 barg (At tie-in point from ESI-1 and ESI-2)
Temperature = 53 oC

Pipeline CO2 Specifications:

Pressure = 190 barg

Max. H2O content = 40 lb/MMSCF
(Sat. H2O content at 0 oC approximately 80 lb/MMSCF)
(Min. Water content can be obtained by JT valve
method without hydrate formation and/or CO2
condensation.)

Air Temperature for Air Cooler Design :

Max. Summer = 48 oC
Min. Winter = 4 oC

7.0 S IMULATION CAS ES REVIEWED AND CHECKED

The following Rev. A6 simulation cases were reviewed and checked for pressure
drop in 24” diameter transfer lines:

1. ESI CO2 COMPRESSION - OPTION 1HA – 24 INCH TRANSFER LINE, 100 %

SUMMER (A6).HSC
2. ESI CO2 COMPRESSION - OPTION 1HA – 24 INCH TRANSFER LINE, 100 %
WINTER (A6).HSC
3. ESI CO2 COMPRESSION - OPTION 1HA – 24 INCH TRANSFER LINE,
SUMMER (50 % ESI-1, 50 % ESI-2)(A6).HSC
4. ESI CO2 COMPRESSION - OPTION 1HA – 24 INCH TRANSFER LINE,
WINTER (50 % ESI-1, 50 % ESI-2)(A6).HSC

The following Rev. A6 simulation cases were reviewed and checked for
Compression and Dehydration Trains:

5. ESI CO2 COMPRESSION - OPTION 1HA – 100 % SUMMER (A6, ONE

TRAIN).HSC
6. ESI CO2 COMPRESSION - OPTION 1HA – 100 % WINTER (A6, ONE
TRAIN).HSC
7. ESI CO2 COMPRESSION - OPTION 1HA – 50 % SUMMER (A6, EQUAL
TRAIN).HSC
8. ESI CO2 COMPRESSION - OPTION 1HA – 50 % WINTER (A6, EQUAL
TRAIN).HSC

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8.0 VERIFICATION OF RES ULTS

The pressure drop through 24” transfer line was carried out using HYSYS pipe
segment program that includes the vapor density changes along the line in the
segmental calculations. There were preliminary isometric sketches developed by our
piping
department from the tie-in point (upstream of the existing pressure control valve on the
existing 16” line to the thermal oxidizer) at the existing ESI site to the inlet to the new
LP stage 1st compressor at the ESNAAD site for both ESI-1 and ESI-2 transfer lines.
The total equivalent feet of pipe (including fittings) 1.3 km and 1.7 km were used in
transfer lines pressure drop calculations for ESI-1 and ESI-2 transfer lines respectively,
extracted from the preliminary isometrics sketches developed by our piping group. The
flow rate used 110 % of the normal flow in calculating the transfer lines pressure drop.
The pressure 0.5 barg were used at the tie-in point at the existing site.

The pressure drop calculation for the transfer lines were checked for all the various
operating cases and the results are correctly shown on Rev.B1 Process Flow
Diagrams and Heat and Material Balance as stated in reference under Section 4.

The compression and dehydration simulations for all four different operating cases
were also checked and verified against the product specifications requirement. The
feed composition, flow rate and the feed properties were also checked against the
simulation input and they were all correct. The simulations are done correctly and no
errors were found. The simulations result for the different operating cases can be seen
on the Rev. B1 Process Flow Diagrams and the Heat and Material Balance as stated in
reference under Section 4. The simulation files for all the four cases are already
provided to PMT for their review.

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