Doosan Babcock
Two-Stage Tray Scrubber and Direct Contact Cooler for Carbon Capture Plant
Project Overview
ERG Air Pollution Control supplied specialist gas treatment equipment for Doosan Babcock as part of a carbon capture and storage (CCS) plant at Ferrybridge Power Station in the UK.
Delivered in 2011, the project incorporated a two-stage tray scrubber, direct contact cooler, liquor storage tanks and control instrumentation.
The equipment was designed for a gas flow rate of 22,000 m³/hr, providing gas conditioning and wet scrubbing capability within the carbon capture plant.
The installation demonstrates ERG’s experience in supplying engineered gas treatment systems for power generation and carbon capture applications, where large-volume process gas streams require controlled cooling and treatment.
The Challenge – Gas Conditioning for Carbon Capture
Carbon capture and storage systems are designed to separate carbon dioxide (CO₂) from industrial or power generation gas streams for subsequent handling, transport or storage.
Depending on the capture technology, the incoming gas may require cooling and treatment before entering downstream carbon capture equipment.
Flue gases from power generation processes can contain moisture, particulate matter and other contaminants that may affect the operation of downstream equipment.
Effective gas conditioning is therefore an important consideration when integrating carbon capture technology with existing power station infrastructure.
At Ferrybridge Power Station, the Doosan Babcock project required gas treatment equipment capable of handling a flow rate of 22,000 m³/hr.
The specified equipment included a direct contact cooler and two-stage tray scrubber, providing complementary gas cooling and wet treatment functions.
The original project case sheet does not identify the specific contaminants targeted, the gas inlet temperature or the required outlet conditions.
ERG’s Solution – Tray Scrubbing and Direct Contact Cooling
ERG supplied a two-stage tray scrubber and direct contact cooler as part of the carbon capture plant’s gas treatment equipment.
Tray scrubbers are wet gas cleaning systems that use internal trays to promote contact between the gas stream and a circulating liquid.
As the gas passes through the scrubber, the trays create controlled gas-liquid interaction, allowing suitable soluble contaminants to transfer into the liquid phase.
A two-stage tray configuration provides sequential gas-liquid contact within the treatment system.
The direct contact cooler provides a separate gas conditioning function by bringing the process gas into contact with a cooling liquid.
This enables heat transfer between the gas and liquid phases, reducing the gas temperature under appropriate operating conditions.
Direct contact cooling can also affect gas moisture content and support preparation of the gas stream for downstream processing.
The combination of cooling and tray scrubbing provides complementary treatment mechanisms within an engineered gas conditioning arrangement.
Equipment Supplied
ERG’s scope of supply included:
Two-stage tray scrubber: Providing gas-liquid contact for wet gas treatment.
Direct contact cooler: Supporting process gas cooling and conditioning.
Liquor storage tanks: Providing storage capacity for process liquids associated with the system.
Control instrumentation: Supporting monitoring and control of the treatment equipment.
The equipment was designed around the specified gas flow rate and formed part of the wider carbon capture and storage plant.
Project Specifications
| Parameter | Project detail |
|---|---|
| Client | Doosan Babcock |
| Site | Ferrybridge Power Station, UK |
| Application | Carbon capture and storage plant |
| Gas flow rate | 22,000 m³/hr |
| Principal technology | Two-stage tray scrubber |
| Additional treatment equipment | Direct contact cooler |
| Supporting equipment | Liquor storage tanks and control instrumentation |
| Year delivered | 2011 |
Applications for Wet Scrubbing in Carbon Capture Systems
Wet gas treatment technologies can play an important role in carbon capture applications where process gases require cooling, conditioning or contaminant removal before further treatment.
Direct contact coolers are used to manage gas temperatures through heat exchange with a cooling liquid, while tray scrubbers provide gas-liquid contact for suitable absorption processes.
The appropriate treatment configuration depends on the gas composition, temperature, flow rate and the requirements of the downstream carbon capture technology.
The Doosan Babcock project illustrates the integration of established wet gas treatment technologies within a carbon capture-related installation at a UK power station.
ERG’s Experience in Power Generation Gas Treatment
ERG Air Pollution Control designs and supplies engineered gas cleaning equipment for industrial and power generation applications.
Its technologies include tray scrubbers, packed tower scrubbers, direct contact coolers and associated process gas treatment equipment.
The Doosan Babcock installation at Ferrybridge Power Station demonstrates ERG’s experience in supplying large-volume gas conditioning and wet scrubbing systems for carbon capture infrastructure.
For further information about tray scrubbers, direct contact coolers or industrial gas treatment systems for carbon capture applications, contact ERG Air Pollution Control.
