Pioneering Carbon Capture Utilisation Plant officially opened in Cheshire
Article posted on: 26 June 2022
This ground-breaking scheme at Tata Chemicals Europe’s (TCE) Northwich site in Cheshire is currently the UK’s largest carbon capture and utilisation facility.
Announced by the Minister for Clean Energy and Growth back in 2019, the carbon capture and utilisation (CCU) facility commenced on site in late March 2020 and supports the UK’s target to bring all greenhouse gas emissions to net zero by 2050.
The new plant is designed to remove carbon dioxide from the emissions generated at the company’s combined heat and power plant. The captured gas is then liquefied and purified for use to manufacture sodium bicarbonate.
The plant, which was officially opened on 24th June 2022 by Mike Amesbury M.P, has been operational since Autumn 2021 and has already captured tens of thousands of tonnes of carbon dioxide emissions and supplied high purity liquid carbon dioxide for TCE’s adjacent sodium bicarbonate manufacturing plant.
Complex scheme
The team at Clancy, led by Divisional Director Graham Ellis and Associate Paul Fleming, was responsible for the site investigation, geotechnical assessment and detailed civil and structural design, for the 40,000sqft plant, constructed on a 1.8-acre plot.
This included a 340m2 substation with four integral transformer bays and a 745m2 fully bunded specialist liquefaction building. The focal point of the site is the 48.5m tall absorber tower which shares a large piled and bunded foundation with the adjacent process towers. We also provided superstructure and foundation designs for some 155m of pipe bridges, including several road crossings and an extensive maintenance platform over the CO2 storage tanks.
On the civil works, we designed and detailed the drainage and external slab areas, including areas of rainwater storage to provide cost-effective SUDS drainage.
Working collaboratively with project team, the construction of this complex scheme has been carefully choreographed around live manufacturing operations on the Winnington site.
Graham Ellis explained, “In developing the structural scheme, we worked closely with the client’s own process and piping engineering teams to fully co-ordinate the integration of the process and equipment within the building envelope. Particular consideration was given to the sequencing of the build works, such that they allowed for the installation of large-scale equipment which would not be possible following the completion of the building. This required the structural scheme to be adapted to allow this sequencing to be facilitated.”
A high standard of health and safety performance was maintained, despite the challenging working environment. Paul Fleming reflected, “The outbreak of Covid brought numerous challenges. The fact the site works continued, issues resolved and challenges were tackled, is a testament to the strength of the team. With a project of this nature, it’s the coordination of the small things that keep it moving efficiently. From day one of our involvement we were in the thick of it, piecing together the information required for our design and providing solutions. We even attended supplier meetings in Denmark in support of TCE in advancing the design.”
Sustainability at the fore
We developed a cost-effective sustainable urban drainage solution for the new development due to the Northwich site being highly susceptible to flooding issues.
For the civil and structural design, we are constantly targeting the ‘Reduce, Re-use, Recycle’ mantra. We were continually assessing our designs to make them as lean as possible and considering different structural forms. Where possible, recycled materials were considered and materials used which were considered to be routinely recyclable. On the superstructure, our biggest sustainability success was in the substantial modification of the link pipe bridge to carry the new, large diameter steam pipework.
The scheme is driven by environmental objectives but still focused on cost efficiency. For the UK, this is innovative technology and the successful implementation provides the opportunity to learn more and achieve more. This is highlighted by the vision and awareness to incorporate future expansion.
Embracing Innovation
There were numerous ‘out of the ordinary’ elements on this scheme, these included challenging ground conditions, demountable roof areas, surface water storage solutions, fully bunded building areas and large bund volume external areas. However, there is no doubt that the process element of this project celebrates a high level of innovation. As civil and structural design engineers, our drivers were on lean efficient design, minimising materials and focusing on buildability and maintainability.
Commenting on the project, Ladan Iravanian, Projects Director at Tata Chemicals Europe said, “We have called upon Clancy for quality engineering advice and support for many years and have proven to be a reliable and professional partner during their involvement in our projects.
“The Carbon Capture and Utilisation Plant is a pioneering, landmark scheme for Tata Chemicals Europe, the largest of its kind in the country, contributing to the UK government’s target of net zero carbon emissions by 2050. The new plant will remove carbon dioxide from TCE’s combined heat and power plant emissions. The gas will then be liquified and purified for use in the manufacturing of high purity sodium bicarbonate for use primarily in kidney dialysis and pharmaceutical applications.”
Ladan, added, “The Clancy team has delivered a professional and reliable design service, embracing advanced and innovative technology, and providing effective solutions to reflect the needs of the project and all stakeholders involved.
“We have valued their contribution and close working relationship with the rest of the TCE team throughout the project, particularly with the challenges encountered over the past 12-months, and we look forward to continuing our working relationship with the team on future projects.”
Future plans
The scheme is part of a bigger picture for investment in the Northwich area. Future proofing was a major consideration during the design. Where practicable, consideration was to be given to the possibility of a second facility in the future. We were therefore offered advice to ensure provision for this in the course of the scheme.
Tata Chemicals Europe is integral to the local community and the Cheshire region, plus a major employer operating several sites intrinsically linked to the history of Northwich. This project is a huge example of TCE’s continued commitment to the area.
Graham concluded, “Our involvement at the Winnington works goes back over 15-years and we have worked on several of TCE’s facilities over the years. Our appointment on the scheme reflects our commitment to climate, energy and the environment, and our involvement in delivering this truly innovative scheme has provided the team with a deeper breadth of knowledge and understanding of carbon capture and utilisation technology.”