Prudentia replaced an existing CO2 absorption vessel that was at end of life with a larger diameter vessel to support a 30% capacity increase through the CO2 removal train. Additional debottlenecking studies on the rest of equipment within the train were performed to identify what additional equipment might be required to be upgraded to meet this capacity increase considering the process changes imposed by the CCS project.
Prudentia were originally engaged to perform a FEED to define the scope required to replace a CO2 absorber vessel on the Train 6 that was approaching end of life. The replacement vessel was due to be installed in a turnaround where additional train modifications were being made to the regeneration plant due to higher column pressures being required to be made for the CCS project. Extensive crane studies were performed to develop a preferred lift plan, but due to access issues and the vessel weight (~100 tonne), the vessel was required to be delivered/installed on site in two pieces. This required extensive interfacing with the vessel fabricator to achieve an acceptable design, lift and on-site weld plan. The tie-in of this new vessel including all piping, civil, structural and instrumentation design was taken through to IFC including all associated construction scopes of work. Additional work including reversing flow through a gas:gas heat exchanger which required a fitness for service assessment was also performed.
This replacement vessel was a larger diameter vessel which accommodated a 30% increase in capacity to match the existing regenerator column capacity. Prudentia worked extensively through concept/assess phase to identify equipment that might need to be replaced or upgraded and benchmarked heat exchanger performance to reduce fouling factors. This was performed for both Trains 5 and 6 and taken to FEED level and will be executed when required according to production profiles.
A similar Train 5 absorber replacement design is currently being performed.